Head Meltshop – General Manager (Steel Melting Shop)

Position: Head Meltshop – General Manager (Steel Melting Shop)

Location: Pokhariya, Birgunj, Parsa, Narayani, Nepal
Reports to: Plant Head

Role Summary

The Head Meltshop is accountable for the complete performance of the Steel Melting Shop (SMS), owning end-to-end operations across induction furnaces, secondary refining (LRF/AOD), and continuous casting. This role is responsible for consistently delivering production targets, optimal cost per ton, metallurgical quality, and zero-harm safety standards.

The position demands a hands-on leader who can drive furnace efficiency, control metallurgical processes, optimize energy consumption, and ensure high-quality billet/slab output for downstream rolling mills—while building and leading a high-performance shop-floor team.

Key Responsibilities

End-to-End SMS Operations

Lead complete SMS operations including Induction Furnace (IF), LRF/AOD refining, and Continuous Casting Machine (CCM).
Ensure smooth coordination between melting, refining, and casting for uninterrupted production flow
Drive daily, weekly, and monthly production planning and execution

Charge Mix & Melt Planning

Develop and optimize charge mix strategies (scrap, sponge iron, alloys) to balance cost and quality
Oversee scrap preparation and segregation to improve consistency and yield
Plan heats to ensure chemistry accuracy and minimal rework

Metallurgical Quality Control

Ensure consistent steel chemistry and adherence to grade specifications
Monitor slag practices, deoxidation, and alloy additions
Drive chemistry hit rate improvements and minimize rejections

Energy Optimization & Yield Improvement

Control and reduce specific power consumption (kWh/ton)
Improve scrap-to-metal yield % through process optimization
Benchmark furnace efficiency and implement best practices

Process Control & Temperature Management

Maintain strict control over melting cycles, tapping temperatures, and superheat
Optimize LRF/AOD cycle times and refining efficiency
Ensure casting temperatures align with CCM requirements

Furnace & Refractory Management

Manage furnace lining practices, refractory selection, and campaign life
Monitor and improve lining life and maintenance cycles
Oversee ladle fleet management and refractory health

Troubleshooting & Maintenance Coordination

Quickly resolve electrical, mechanical, and process-related issues
Coordinate closely with maintenance teams to minimize downtime
Lead root cause analysis (RCA) and implement corrective actions

Continuous Casting & Downstream Quality

Ensure high-quality billet/slab production suitable for rolling mills
Minimize casting defects and improve CCM quality metrics
Align SMS output with rolling mill requirements

Production Planning & Reporting

Track and report production, energy, yield, and quality KPIs
Analyze trends and drive continuous improvement initiatives
Ensure accurate shift-wise and daily reporting

Team Leadership

Lead and develop shift engineers, furnace operators, and technicians
Build a disciplined, performance-driven shop-floor culture
Train teams on best practices, safety, and process control

Safety & Compliance

Enforce strict adherence to safety protocols and zero-incident culture
Ensure compliance with pollution control and environmental norms
Lead safety audits and incident investigations

Technical Expertise Required

Strong hands-on experience in medium/high frequency induction furnace operations
Deep understanding of metallurgy (scrap behavior, alloys, slag chemistry)
Proven ability to optimize power consumption (kWh/ton benchmarks)
Expertise in secondary refining (LRF/AOD processes)
Strong knowledge of continuous casting operations (CCM)
Experience in refractory management and furnace lining practices
Familiarity with pollution control systems and compliance standards

KPIs / Performance Metrics

Total liquid steel production (tonnes/day)
Scrap-to-metal yield (%)
Power consumption (kWh/tonne)
Chemistry hit rate (%)
Furnace lining life / campaign life
LRF/AOD cycle time
CCM quality (defects, rejections)
Unplanned downtime reduction
Rejection rate (%)
Safety performance (zero incidents, audit scores)
Candidate Profile

Education: B.Tech / B.E. in Metallurgical Engineering (preferred) or Mechanical Engineering
Experience: Minimum 15+ years in Steel Melting Shop (SMS) operations

Mandatory hands-on experience in:
Induction Furnace (IF) operations
Secondary refining (LRF/AOD)
Continuous Casting (CCM)
Proven experience in large-scale SMS leadership roles
Experience in plant setup, expansion, or commissioning will be a strong advantage

Leadership Expectations

Strong shop-floor command and decision-making ability
Ability to build, train, and scale teams from the ground up
Excellent problem-solving under pressure
Data-driven mindset with focus on cost, quality, and productivity
High ownership and accountability for plant performance

Interested candidates may send their CV to: hr@primesteel.com.np
Subject Line: Application for Head Meltshop