Method Engineer

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 Job Description Method Engineer (Casting Shop) | Page 1 BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings ¢ 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. Job Description Method Engineer (Casting Shop) | Page 2 BEHARI LAL ENGINEERING LIMITED Alloy & Steel Castings ¢ 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. Job Description Method Engineer (Casting Shop) | Page 3