JOB DESCRIPTION –Furnace Operator
Department: Melting / Foundry
Industry: Ductile Iron Pipe Manufacturing
Reports to: Induction Furnace Engineer / Melting Supervisor
Shift: Rotational (as required)
Job Purpose
To operate, monitor, and maintain the Induction Furnace system used for melting scrap and pig iron for ductile iron pipe production, ensuring safe, efficient, and continuous furnace operation with strict process control.
Key Responsibilities
Furnace Operation
- Operate medium frequency induction furnaces as per melting schedule.
- Able to handle multi task / more then one function . Also, Training employees to perform different job functions.
- Responsible for all activities of melting section.
- Responsible for proper quantity of alloy addition to the furnace.
- Charge scrap, pig iron, ferro alloys, and additives as per charge mix instructions.
- Monitor melt temperature, chemical composition , superheat, power consumption, and melting time.
- Assist in tapping molten metal into ladles safely and efficiently.
- Ensure proper slag removal and maintain slag condition.
- Record all melting parameters in SCADA.
Equipment Inspection & Maintenance
- Perform routine inspection of furnace coils, lining, cooling system, and power supply units.
- Check water-cooling systems, pumps, and flow meters for proper operation.
- Report any abnormal noise, vibration, overheating, or leakage to maintenance engineers.
- Assist during coil replacement, lining installation, and refractory checks.
- Clean furnace pit, platform, and work area regularly.
Safety & Compliance
- Follow all safety procedures related to molten metal handling and furnace operation.
- Use PPE: face shield, aluminized jackets, gloves, heat-resistant boots, etc.
- Ensure proper grounding and interlock functioning before furnace start.
- Adhere to ISO, 5S, and plant safety standards.
Process Control & Quality
- Monitor chemical composition and adjust alloys during melting.
- Maintain target carbon, silicon, magnesium (for DI), and temperature as instructed.
- Coordinate with the metallurgy/quality department for sample analysis.
- Ensure molten metal quality is suitable for centrifugal casting and finishing operations.
Documentation & Reporting
- Maintain furnace daily operation logs (temperature, power, input materials, downtime).
- Report furnace downtime, failures, and production delays.
- Document refractory life, coil performance, and melting efficiency.
Skills & Competencies Required
- Knowledge of induction furnace operation (medium/high-frequency).
- Understanding of melting practice for ductile iron.
- Ability to read process parameters and interpret melt chemistry.
- Basic electrical & mechanical troubleshooting skills.
- Familiar with hydraulics, cooling systems, and PLC basics (optional).
- Strong safety awareness and teamwork.
Qualifications & Experience
- ITI in Foundry, Metallurgy, Mechanical, Electrical, or relevant trade.
- 5–10 years experience in induction furnace operations (preferably in ductile iron/steel foundry).
- Experience with 10–20 ton furnaces is an added advantage.
Physical Requirements
- Ability to work in high-temperature environments.
- Comfortable with heavy PPE.
- Ability to work in rotating shifts.
Work Environment
- Foundry melting shop with high heat, dust, and noise levels.
- Coordination with casting, metallurgy, and maintenance teams.
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