Head Foundry

Mavenhasten Consulting; Bengaluru; On-site; INR 350,000 - 550,000; Full time

Job summary

Mavenhasten Consulting is seeking an Operations Leader for our Bengaluru foundry, responsible for bronze to stainless steel casting transitions, automation initiatives, and end-to-end performance across safety, quality, delivery, and cost metrics.

You will partner with engineering, supply chain, and finance to drive continuous improvement and capital project execution while maintaining compliance with regulatory requirements and a focus on people development and lean transformation.

Qualifications

• Bachelor's degree in mechanical/environmental/industrial related field and 15-18 years in foundry/casting ops, with leadership.
• Experience with automation transitions and material/process changes.
• Knowledge of ferrous and non-ferrous casting processes and foundry equipment.

Responsibilities

• Lead foundry manufacturing activities including bronze and stainless steel casting operations.
• Drive automation roadmap and supplier relationships to improve efficiency, quality, and cost.
• Coordinate production workflows and lean improvement programs across multiple functions.
• Oversee safety, quality, delivery, and financial performance in the foundry.
• Collaborate with engineering, supply chain, and finance on budgets and strategic plans.
• Ensure compliance with environmental, health and regulatory requirements.

Skills

Foundry operations

Automation implementation

Lean manufacturing

Project management

Supply chain management

ERP/MRP systems

Change management

Team leadership

Education

Bachelor's Degree in Mechanical Engineering

Tools

MS Office

ERP/MRP systems

Job description

Role & responsibilities

Operations Leadership & Performance:

• Lead all foundry manufacturing activities including bronze impeller production using both machine core and hand core processes, ensuring consistent quality, on-time delivery, and cost efficiency.
• Provide strategic direction and operational oversight for the transition from bronze to stainless steel casting capabilities by conducting feasibility studies, process development, and qualification activities.
• Drive achievement of key performance metrics including safety, quality, delivery, cost, and productivity targets across all production areas [Automation & Operational Excellence] including sustainability initiatives that reduce waste, energy consumption, and environmental impact [Financial Management & Strategic Planning].
• Support and lead the automation transformation roadmap for the foundry, identifying and implementing technologies that improve efficiency, quality, and capacity.
• Work with engineering teams to design, specify, and commission automated systems for core making, casting, finishing, and material handling processes including to ensure new material capabilities meet customer requirements and quality standards.
• Coordinate changes to production workflows and layouts to maximize the benefits of automation investments.
• Lead/sponsor continuous improvement initiatives using lean manufacturing principles and problem-solving methodologies [Operations, Supply Chain & Inventory Management].
• Support optimization of secondary supplier relationships for raw materials, consumables, tooling, and outsourced services to ensure quality, reliability, and cost competitiveness.
• Work with supply chain teams to create and monitor inventory management plans that maintain 95% safety stock availability in the HUB at all times.
• Coordinate changes to procurement strategies and supplier partnerships that reduce lead times and improve material flow.
• Participate in supplier development programs and quality improvement initiatives with key vendors.

People Development & Employee Relations:

• Support the development of a highly skilled, engaged, and motivated workforce through effective talent management, training programs, and career development initiatives.
• Work with HR teams to create and monitor employee engagement strategies that build trust, transparency, and open communication across all levels.
• Coordinate changes to compensation, benefits, and recognition programs that are competitive and equitable.
• Participate in the cultivation of a positive workplace culture that emphasizes safety, respect, collaboration, and continuous learning, reducing the risk of unionization through proactive employee relations [Material Transition Strategy].
• Support the maintenance of world-class safety performance with a goal of zero incidents through robust safety management systems and continuous risk assessment.
• Work with quality teams to create and monitor quality assurance processes that ensure 100% conformance to customer specifications and industry standards.
• Coordinate changes to ensure full compliance with all environmental, health, safety, and regulatory requirements.
• Support the development and management of annual operating budgets, capital investment plans, and financial forecasts for the foundry.
• Work with finance teams to create and monitor cost reduction initiatives and productivity improvement programs that enhance profitability.
• Coordinate changes to manufacturing strategies aligned with corporate objectives and market demands.
• Participate in business reviews with senior leadership, providing insights and recommendations on operational performance and strategic opportunities.

To thrive in this role, you should bring:

• Bachelor's Degree in Mechanical Engineering, Metallurgical Engineering, Industrial Engineering, Manufacturing Engineering, or equivalent technical discipline.
• 15-18 years of progressive experience in foundry or casting operations, with at least 5-7 years in senior leadership roles managing engineering, manufacturing, and distribution operations in an industrial environment.
• Demonstrated knowledge of ferrous and non-ferrous casting processes, metallurgy principles, foundry equipment, and industry best practices.
• Proven track record of leading operational transformations, including automation implementation and material/process transitions.
• Experience managing multi-cultural teams and driving change in complex organizational environments.
• Knowledge of Indian labor laws, industrial regulations, policies, and procedures.
• Experience with lean manufacturing, Six Sigma, or other continuous improvement methodologies strongly preferred.

Technical Skills

• Deep understanding of foundry operations including pattern making, core making, melting, pouring, heat treatment, finishing, and quality control processes for bronze and stainless steel castings.
• Proficiency in manufacturing technologies, automation systems, and Industry 4.0 concepts applicable to foundry environments.
• Strong knowledge of supply chain management, procurement strategies, inventory optimization, and supplier quality management.
• Proficiency in Microsoft Office Suite and familiarity with ERP/MRP systems.
• A self-starter attitude with the ability to work independently and make sound decisions in a dynamic environment.
• Creative problem-solving skills and the ability to manage conflicts and navigate challenges within various organizational structures.
• Project management capabilities with experience leading capital projects and operational improvement initiatives.

Soft Skills

• The capability to simplify complex problems, conduct root cause analysis, and provide clear, well-thought-out recommendations that drive business results.
• Team-oriented leadership skills with a demonstrated ability to build, develop, and inspire high-performing teams across multiple functions.
• Excellent communication and influencing skills, with the ability to engage effectively with employees at all levels, senior executives, customers, and external stakeholders.
• Cultural sensitivity and emotional intelligence to lead diverse teams and foster an inclusive workplace environment.
• Strong business acumen with the ability to balance operational excellence, customer satisfaction, employee engagement, and financial performance.
• Change management expertise with a track record of successfully leading organizations through significant transformations.
• Strategic thinking combined with hands‑on execution capability to drive both long‑term vision and short‑term results.