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Fettling Supervisor – WNCFS14072026
Company Overview
The Company is one of India’s leading manufacturers of engineering cast components, supplying high-quality metal parts for Railway Engineering, Automobile Engineering, General Engineering, and Agriculture applications. With strong foundry and quality systems, the Company delivers reliable castings that meet Indian and international quality standards and is trusted for consistent quality, safe products, and timely delivery across industries.
Job Overview
The Fettling Supervisor is responsible for overseeing the finishing operations of cast components in the foundry, ensuring that all products meet defined quality and surface standards before dispatch. The role involves managing fettling processes such as grinding, chipping, and shot blasting, while maintaining high levels of productivity, safety, and efficiency on the shop floor. The supervisor plays a critical role in coordinating with production and quality teams to minimize defects, reduce rework, and ensure timely delivery of components used across railway, automobile, agriculture, and general engineering applications. Additionally, the role focuses on workforce management, process improvement, equipment utilization, and adherence to company quality systems and safety norms, ensuring consistent output aligned with both Indian and international standards.
Key Responsibilities
- Supervise day-to-day fettling activities including knockout, degating, cutting, chipping, grinding, shot blasting, dressing, and final finishing of cast components.
- Ensure removal of runners, risers, gates, flash, burrs, sand inclusions, and surface defects as per drawings and specifications.
- Manage the complete fettling process flow from knock-out to final finishing and dispatch readiness.
- Plan and execute daily fettling schedules to meet production targets across Railway, Automobile, Agriculture, and General Engineering components.
- Allocate tasks to fettling operators, grinders, shot blast operators, and helpers based on skill level and workload.
- Monitor productivity, efficiency, cycle time, and machine utilization to achieve daily and shift-wise targets.
- Optimize manpower deployment and ensure maximum utilization of machines and resources.
- Identify bottlenecks and implement improvements to enhance output and reduce non-value-added activities.
- Ensure all fettled castings meet dimensional accuracy, surface finish, and customer specifications as per IS, ASTM, and international standards.
- Conduct in-process and final inspections to verify quality before dispatch.
- Identify defects such as cracks, porosity, blowholes, sand inclusions, and improper finishing.
- Coordinate with Quality Control teams for inspections, NDT preparation, and corrective actions.
- Minimize rejection and rework through continuous monitoring and process improvements.
- Analyze root causes of defects and provide feedback to foundry, molding, and melting teams to improve casting quality.
- Implement process improvements to reduce cycle time, improve surface finish, and enhance productivity.
- Suggest automation opportunities and improved tools or abrasives for operational efficiency.
- Supervise and manage both permanent and contract workforce in the fettling department.
- Handle shift planning, attendance, discipline, and performance monitoring.
- Train and guide operators on fettling techniques, tool usage, and quality requirements.
- Ensure adherence to standard operating procedures and best practices.
- Enforce safety practices including PPE usage such as goggles, gloves, masks, and ear protection.
- Ensure safe handling of grinding machines, pneumatic tools, and shot blasting equipment.
- Monitor dust control systems, ventilation, and overall workplace safety conditions.
- Conduct regular safety checks and ensure compliance with HSE standards.
- Ensure proper usage and maintenance of fettling tools, grinders, and shot blasting equipment.
- Monitor consumption of grinding wheels, cutting discs, electrodes, and shot media.
- Coordinate with maintenance teams for preventive maintenance and breakdown resolution.
- Ensure proper handling of castings to avoid damage during fettling operations.
- Maintain 5S standards and housekeeping in the fettling shop floor.
- Ensure proper segregation and disposal of waste materials and abrasives.
- Coordinate with production, foundry, heat treatment, quality, and dispatch teams for smooth workflow.
- Ensure timely movement of castings and adherence to delivery schedules.
- Escalate operational issues or delays affecting production timelines.
- Maintain daily production reports, rejection reports, rework data, and downtime analysis.
- Track manpower utilization and operational efficiency metrics.
- Ensure traceability of castings through heat numbers and batch codes.
- Support audits, inspections, and compliance documentation requirements.
- Ensure adherence to company quality systems, ISO standards, and customer-specific requirements.
- Maintain audit-ready processes aligned with industry best practices.
Key Skills
- In-depth knowledge of fettling processes including knockout, degating, cutting, chipping, grinding, shot blasting, dressing, and finishing of cast components.
- Strong understanding of foundry and casting processes such as sand casting, SG iron, grey iron, and steel castings.
- Expertise in identifying and rectifying casting defects including porosity, blowholes, cracks, shrinkage, sand inclusions, fins, and flash.
- Ability to read and interpret engineering drawings, blueprints, tolerances, and technical specifications.
- Strong knowledge of surface finish requirements, dimensional accuracy, and visual quality standards.
- Hands-on experience with fettling tools and equipment such as pneumatic grinders, swing frame grinders, cutting machines, and shot blasting systems.
- Knowledge of abrasive technology including grinding wheels, cutting discs, and shot blasting media selection and usage.
- Proficiency in using measurement instruments like vernier calipers, micrometers, and gauges for inspection.
- Strong quality control and inspection skills with focus on defect prevention and first-pass yield improvement.
- Knowledge of NDT preparation and coordination with quality teams for inspections and approvals.
- Familiarity with ISO 9001, IATF 16949, and other quality management systems and customer-specific standards.
- Strong problem-solving and root cause analysis skills for addressing quality issues and process inefficiencies.
- Ability to implement corrective and preventive actions to reduce rejection and rework.
- Production planning and shop floor management skills to achieve daily and shift-wise targets.
- Ability to monitor productivity, cycle time, and optimize manpower and machine utilization.
- Knowledge of lean manufacturing, Kaizen, and 5S practices for continuous improvement.
- Strong leadership and team management skills to handle skilled, semi-skilled, and contract workforce.
- Experience in manpower planning, shift scheduling, and performance monitoring.
- Ability to train, mentor, and develop shop floor operators on technical and safety practices.
- Strong understanding of safety protocols, PPE usage, and HSE compliance in foundry operations.
- Knowledge of dust control systems, ventilation, and environmental safety standards.
- Equipment maintenance awareness including preventive maintenance and coordination for breakdowns.
- Consumables management skills to monitor usage and control cost of grinding wheels, abrasives, and shot media.
- Strong coordination and communication skills for cross-functional collaboration with production, quality, and maintenance teams.
- Ability to maintain production reports, MIS, rejection analysis, and audit documentation.
- Basic computer skills including MS Office for reporting and data tracking.
- Strong analytical mindset for productivity improvement, cost reduction, and process optimization.
- High attention to detail and quality-focused approach to ensure zero-defect output.
- Ability to work under pressure and meet strict delivery timelines in a fast-paced foundry environment.
- Adaptability to new technologies, automation, and process innovations in fettling operations.
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Salary
₹30000/- to ₹60000/- pm (Best in the Industry for Qualified Candidate)
Industry
Foundry and Metal Casting Manufacturing Industry
Age Limit
Maximum 40 Years
Gender Preference
Male Only
Education
Any BE / Diploma / ITI in Mechanical Engineering / Metallurgy / Production Engineering / Fitter / Turner / Grinder / Foundryman with relevant supervisory knowledge in casting or foundry operations. Certification or training in Foundry Technology or Casting Processes is an added advantage. Basic knowledge of quality standards such as ISO or IATF through formal training is preferred. Priority will be given to candidates with foundry and metal casting industry knowledge related to Automobile Engineering, Railway Engineering, General Engineering, Agriculture Equipment, Heavy Engineering, Industrial Machinery, Defense and Aerospace, Manufacturing and Fabrication, and Material Processing.
Experience
Any Candidate with 1 to 4 years of experience in the Foundry / Casting industry with hands-on exposure to fettling operations. Minimum 1 to 2 years of experience in a supervisory role handling fettling shop floor activities. Experience in handling cast components for Railway, Automobile, Agriculture, or General Engineering sectors. Strong exposure to grinding, shot blasting, finishing, and defect handling processes. Experience in managing manpower, shift operations, and achieving production targets. Familiarity with quality standards, inspection processes, and rejection control. Experience in implementing safety practices and maintaining shop floor discipline. Experience working in ISO or IATF certified manufacturing environments will be preferred. Priority will be given to candidates with foundry and metal casting industry experience related to Automobile Engineering, Railway Engineering, General Engineering, Agriculture Equipment, Heavy Engineering, Industrial Machinery, Defense and Aerospace, Manufacturing and Fabrication, and Material Processing.
Location
Near Ahmedabad - Gujarat | India
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