Head - Production/Safety/Quality/Cost - Steel Melting Shop

Description:

To drive and ensure efficient end-to-end Carbon Steel (Steel Melting Shop) operations across BOF, LRF, and Continuous Casting, delivering excellence in productivity, quality, cost, and safety. The role is responsible for operational execution, process stabilization, and continuous improvement to support the scale-up and sustained performance of Carbon Steel operations.

Accountability Expected Outcome Performance Measures

End-to-End Production Planning & Throughput

- Seamless BOFLRFCaster synchronization with optimized flow and minimal bottlenecks

- Throughput (TPH), heat turnaround time, ladle turnaround time, schedule adherence (%)

BOF Operations Excellence & Productivity

- Stable converter operations with precise end-point control and high productivity

- End-point hit rate (%), reblow frequency, slopping incidents, converter turnaround time, lining life (heats)

Secondary Metallurgy (LRF) Refining & Quality Control

- Consistent achievement of target chemistry, temperature, and steel cleanliness

- Chemistry hit rate (%), treatment time, power consumption (kWh/ton), inclusion levels, ladle turnaround time

Continuous Casting Performance & Yield

- Stable casting with minimal defects and optimized yield

- Casting speed, strand availability (%), breakout frequency, rejection/downgrade %, yield (%)

Cost Optimization & Resource Efficiency

- Reduction in cost per ton through optimized resource

- Conversion cost/ton, alloy consumption, power consumption, utilization refractory consumption, yield (%)

Quality Assurance & Product Consistency

- Consistent adherence to grade specifications and reduced variability

- Customer complaints, defect rate (%), internal rejection %, variability in chemistry/mechanical properties

Cross-Functional Integration

- Strong alignment across Iron Making, Rolling, Maintenance, and support functions

- Production plan adherence, downtime due to coordination issues, cross-functional SLA adherence

Safety, Environment & Compliance

- Safe operations with zero incidents and full regulatory compliance

- LTIFR, TRIFR, near-miss reporting, audit compliance score, environmental KPI adherence

Process Excellence & Digitalization

- Improved process stability through analytics, automation, and continuous improvement

- Number of CI projects completed, cost savings, process variability reduction, APC/Digital adoption rate

People Leadership & Capability Building

- High-performing, skilled, and future-ready team

- Employee productivity, training hours/employee, internal promotions %, attrition rate, succession coverage

3. Key Challenges

1. Establishing stable and efficient BOFLRFCaster operations in a new Carbon Steel setup.

2. Managing variability in hot metal quality from Iron Making.

3. Achieving global benchmarks in yield, productivity, and cost during ramp-up phase.

4. Reducing defects and ensuring consistent steel cleanliness.

5. Maintaining a zero-harm safety environment in high-risk operating conditions.

4. Key Decisions

Made by Job holder

1. BOF blowing parameters and scrap/hot metal mix strategy.

2. LRF refining practices, alloying strategy, and treatment cycles.

3. Casting parameters, sequencing, and production planning.

4. Resource allocation, shift planning, and operational priorities.

5. Process improvement and cost optimization initiatives.

Recommendations to Supervisor / Seniors in Hierarchy

1. Capital investments (technology upgrades, automation, capacity expansion).

2. Introduction of new grades and product mix strategy.

3. Long-term cost optimization and sourcing strategies.

4. Organizational design and capability-building initiatives.

Internal Interactions

- Iron Making (RMHS, Sinter, Blast Furnace)

- Rolling Mills / Finishing Units

- Maintenance (Mechanical, Electrical, Automation)

- Quality & Metallurgy Teams

- Procurement & Commercial dept.

- Finance dept.

- HR dept.

External Interactions

- Technology providers and OEMs (BOF, LRF, Casting equipment)

- Industry experts and consultants

- Regulatory authorities

6. Skills, Knowledge & Experience Required

- Educational Qualification B Tech (Metallurgy / Mechanical)

Certification, If any (Supporting the Job Role)

- Advanced certifications in Steel Melting / Secondary Metallurgy (preferred)

- Total Years of Experience 22-25 years of experience in steel manufacturing

Functional Skills:

1. Expertise in BOF, LRF, and Continuous Casting operations

2. In-depth knowledge of refining practices and slag management

3. Proficiency in steel cleanliness and inclusion control techniques

4. Experience in yield enhancement and process optimization

5. Familiarity with DCS/PLC systems and advanced process control