Method Engineer

Behari Lal Engineering Limited; Mandi Gobindgarh; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Behari Lal Engineering Limited is seeking a Method Engineer to own the methoding of steel and alloy steel castings produced on the no-bake sand system. The role covers gating, feeding, pattern/core-box development and yield optimisation for heavy castings up to 25 MT.

The candidate will coordinate external simulation work, develop in-house capabilities, and ensure first-time-right development of new castings. Strong experience with no-bake processes and casting standards is required.

Qualifications

• Diploma/B.E./B.Tech in Metallurgy or Foundry Technology (NIFFT or equivalent preferred).
• Minimum 5 years of methoding / process engineering experience in a steel or alloy steel foundry, preferably on the no-bake sand system and with heavy castings.
• Demonstrated hands-on methoding of medium-to-heavy castings; experience up to the 25 MT range is a strong advantage.

Responsibilities

• Design gating, running and feeding (riser/chill/padding) systems for heavy steel castings (500 kg–25 MT).
• Determine number, size and location of risers, chills, insulation sleeves and cover material for directional solidification.
• Coordinate pattern manufacture with in-house and external shops; review and approve first-off patterns and cores.
• Prepare and maintain method sheets, drawings and process route cards; standardise methods across part families.
• Coordinate solidification/mould-filling simulation with outsourced partner; interpret results to reduce defects and drive yield improvements.
• Lead new casting development from customer drawing to approved first article; interface with pattern, moulding, melting, fettling and quality functions.
• Ensure methoding complies with ASTM/IS/EN and internal quality requirements.

Skills

Casting simulation

CAD tools

Methoding fundamentals

No-bake sand process

Pattern & core-box design

Education

Diploma / B.E. / B.Tech in Metallurgy/Foundry

Tools

MAGMASOFT

ProCAST

AutoCAST

SOLIDCast

AutoCAD/SolidWorks

Job description

BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings

JOB DESCRIPTION

1. Position Summary

The Method Engineer is responsible for the complete methoding of steel and alloy steel castings produced on the no-bake (chemically bonded) sand system, covering casting weights from 500 kg to 25 MT. The role owns the technical design of gating, feeding and risering systems, pattern and core-box requirements, and yield optimisation for a product mix that includes valve and pump bodies, wear parts and general engineering castings. The engineer drives first-time-right development of new castings, reduces methoding-related rejections, and coordinates casting simulation (currently outsourced) with the objective of progressively building this capability in-house.

2. Key Responsibilities

Methoding, Gating & Feeding Design

Design gating, running and feeding (riser / chill / padding) systems for heavy steel and alloy castings (500 kg 25 MT) using modulus and solidification principles.

Determine number, size and location of risers, chills, insulating / exothermic sleeves and cover material to ensure directional solidification and sound castings.

Optimise pouring parameters pouring temperature guidance, pouring time, sprue / ingate ratios in coordination with the melting and pouring teams.

Pattern & Core-Box Development

• Prepare pattern and core-box layouts, defining shrinkage / contraction allowances, machining allowances, draft, core prints and parting arrangement for the no-bake process.
• Coordinate pattern manufacture with in-house and external pattern shops; review, trial and approve first-off patterns and core boxes.
• Maintain pattern equipment records, revisions and physical condition to ensure dimensional accuracy of moulds and cores.

Casting Simulation & Yield Optimisation

• Prepare inputs and coordinate solidification / mould-filling simulation with the outsourced simulation partner; interpret results and iterate the method to eliminate shrinkage porosity, cold shuts and inclusions before pattern release.
• Support the phased development of in-house simulation capability defining requirements, validating results against shop-floor outcomes and building standard practice.
• Drive casting yield improvement and accurate estimation of casting, feeder and pattern weights for costing and enquiry response.

No-Bake Process, Method Sheets & Standardisation

• Specify mould and core parameters for the no-bake system box sizes, mould thickness, hardness, coating and closing requirements.
• Prepare and maintain method sheets, methoding drawings and process route cards, and standardise proven methods across similar part families.

Rejection Analysis & Continuous Improvement

• Analyse casting defects (shrinkage, sand / slag inclusion, blowholes, cracks, mis-run, dimensional) and lead root-cause analysis and corrective / preventive actions for methoding-related rejections.
• Track methoding KPIs and drive measurable reduction in rejection and rework.

New Product Development & Coordination

• Lead new casting development from customer drawing to approved first article, including feasibility, methoding, sampling and validation.
• Interface with pattern shop, moulding, melting, fettling and quality functions, and provide technical support to customers on castability, methoding and design-for-manufacture queries.
• Ensure methoding complies with applicable material and casting standards (e.g. ASTM, IS, EN) and internal quality requirements.

3. Qualifications & Experience

• Education: Diploma / B.E. / B.Tech in Metallurgy, Mechanical or Foundry Technology (NIFFT or equivalent preferred).
• Experience: Minimum 5 years of methoding / process engineering experience in a steel or alloy steel foundry, preferably on the no-bake sand system and with heavy castings.
• Domain: Demonstrated hands‑on methoding of medium‑to‑heavy castings; experience up to the 25 MT range is a strong advantage.

4. Technical Skills & Competencies

• Simulation: Working knowledge of casting simulation software (e.g. MAGMASOFT, ProCAST, AutoCAST or SOLIDCast) essential.
• CAD: Proficiency in CAD tools (e.g. AutoCAD, SolidWorks or Creo) for methoding layouts and pattern drawings essential.
• Methoding: Strong command of methoding fundamentals gating and risering design, modulus method, feeding distance, Chvorinovs rule and directional solidification.
• Process: Sound understanding of the no-bake (furan / alkaline-phenolic) sand system and its influence on casting quality.
• Materials: Familiarity with carbon, alloy and stainless steel grades and relevant casting standards (ASTM / IS / EN).

5. Desirable Attributes

• Exposure to valve / pump body and wear-part castings.
• Experience setting up or bringing simulation in-house.
• Knowledge of casting cost estimation and yield benchmarking.

6. Behavioural Competencies

• Analytical and structured problem-solving with a data-driven approach to defect reduction.
• Strong cross‑functional coordination and clear technical communication.
• Ownership, accountability and a continuous‑improvement mindset.

7. Key Performance Indicators

• Casting yield improvement (%) across the assigned part mix.
• Reduction in methoding-related rejection and rework (%).
• Methoding turnaround time for new enquiries and developments.
• First‑time‑right rate on new casting developments.
• Pattern / method development lead time.

This job description outlines the primary duties of the role and is not exhaustive; responsibilities may evolve with organisational needs.