Engineer VIM & VAR (Aero Castings)

The Engineer, VIM & VAR undertakes the comprehensive responsibility for all activities associated with operation of VIM and VAR ensuring the reliability, efficiency, and optimal performance of various casting manufacturing projects of R&D and NPD department. Engineer, VIM & VAR will bring rich technical expertise in operation and handling of VIM & VAR equipment, with a proven track record in casting development process for R&D and NPD department. A critical aspect of this role involves maintaining documentation of NPD and R&D projects such as NCR sheets, VIM-VAR logbooks, pre-heat checklists, pre-melt checklists, Ingot preparation checklist that are aligning with the stringent SOPs and standards outlined by AS9100 .

Key Responsibilities:

Ensure thorough pre-cleaning of shells before initiating melting and pouring operations.

Oversee the proper wrapping of shells with ceramic materials to maintain quality standards.

Manage the pre-heat oven to ensure proper pre-heating of shells before the melting process.

Handle the operation of the Vacuum Induction Melting machine efficiently as per SOP and defined parameters.

Oversee the preparation of ingots before feeding them into the Vacuum Induction Melting machine.

Ensure the proper preparation and management of documents such as raw material testing reports, method sheets, and SOP documents related to each NPD and R&D.

Prepare and manage documents for VIM operation such as NCR sheets, VIM logbooks, pre-heat checklists, pre-melt checklists.

Prepare critical documents for VAR operation such as shell preparation sheets, shell baking sheets, pre-melt checklists, log sheets for VAR production, weekly NPD production plans, NCR generation, AS9100 documentation, VM board updates, control chart updates.

Effectively handover NPD & R&D castings from one stage to another using SYNCRO.

Conduct Positive Material Identification (PMI) testing on ingots and based on its results, identify raw material specification.

Record results, parameters, and specifications of each iteration/Project at melting section (VIM and VAR) for NPD and R&D department.

Participate in Root Cause Analysis (RCA) for critical NCRs to identify and address underlying

issues.

Ensuring safe work environment within the working area .

Ensuring continuous improvement (Kaizen) and 5S in respective areas.

Desired Candidate Profile

Education and Certifications:

Bachelor of engineering in Metallurgy/Mechanical/Production, or a related field.

Experience:

0-1 years of proven experience of handling melting operation (VIM and VAR) in Production or NPD department for precision casting manufacturing or foundry industry.

Technical / Functional Expertise & other competencies:

Understanding of metallurgical processes related to Vacuum Induction Melting (VIM) and Vacuum Arc Remelting (VAR).

Knowledge of alloy compositions, material properties, and their impact on the casting process.

Experience in preparing and managing various documents, including raw material testing reports, method sheets, SOP documents, NCR sheets, logbooks, checklists, and production plans.

Familiarity with AS9100 documentation requirements.

Ability to troubleshoot and address issues related to VIM and VAR processes, as well as participating in RCA for critical NCRs.

Expertise in conducting Positive Material Identification (PMI) testing on ingots to determine raw material specifications.