Casting Manager - Sourcing

Role Overview:

- Deep metallurgical knowledge of steel and CI casting grades, melting processes.

- Comprehensive understanding of international valve material specifications, including ASTM A216 (WCB), ASTM A351 (CF8M/CF3M), ASTM A217 (WC6/WC9), and ASTM A395 (Ductile Iron).

- Strong knowledge of post-casting operations heat treatment, annealing, stress relieving.

- Proficiency in casting simulation software, methoding and pattern design.

Strategic Sourcing and NPD:

- Establish a robust supplier base capable of pouring specialized pressure-retaining alloys like Duplex, Super Duplex, Inconel, Monel, Hastelloy, and standard carbon/alloy steels (WCB, WC6, LCC) alongside ductile iron.

- Formulate and execute long-term sourcing strategies (new vendors identification and onboarding).

- Lead technical feasibility reviews for pressure-retaining configurations (bodies, bonnets, wedges, gates, discs, and plugs) ensuring adherence to ASME B16.34, API 6D, API 600, and ISO 5208 design standards.

- Review foundry methoding layouts, development of patterns, feeding systems, and casting simulation reports to minimize shrinkage cavity defects in thick-to-thin section transitions common in valve bodies.

- Oversee pattern construction, sample qualification, and pilot batch trials to secure quick turnaround on new product testing and qualification.

- Implement Total Cost of Ownership (TCO) models, market benchmarking, and should-cost analyses.

- Manage commercial RFQs, supplier negotiations, contracts, and long-term price indexation.

- Oversee technical feasibility reviews, drawing/GD&T interpretations, and Design for Manufacturing (DFM) for new casting variants.

Supplier Quality and Development (SQD):

- Onboard qualified foundries through rigorous technical and process audits.

- Audit and qualify foundries to ensure they possess critical regulatory certifications such as ISO 9001, PED 2014/68/EU (Pressure Equipment Directive), and specialized marine or nuclear approvals if required.

- Ensure foundries comply with strict material traceability requirements, including the generation of EN 10204 Type 3.1 and 3.2 Material Test Reports (MTRs).

- Enforce zero-defect quality plans governing Non-Destructive Testing (NDT) processes, including Radiographic Testing (RT), Ultrasonic Testing (UT), Magnetic Particle Testing (MT), and Liquid Penetrant Testing (PT) for pressure integrity.

- Drive process optimization, defect reduction (shrinkage, blowholes, porosity), and Corrective Action Preventive Action (CAPA) frameworks.

- Monitor supplier key performance indicators (KPIs) for delivery, scrap rate, and quality compliance (ISO/ASTM/EN standards).

Key Performance Indicators (KPIs):

- Total Cost Reduction: Year-on-year percentage savings achieved through TCO modeling, should-cost optimization, and yield improvement.

- NPD Time-to-Market: Lead time from engineering drawing release to First Article Inspection (FAI) approval and serial production launch.

- NDT Pass Rate: Percentage of pressure-retaining castings passing initial Radiographic (RT) and Ultrasonic (UT) testing at the foundry stage.

- Supplier Quality Rating: Reduction in scrap rates, casting porosity rework costs, and supplier PPM (Parts Per Million) defects.

- Regulatory Compliance Score: 100% adherence to traceability documentation and audit success rates for PED and API certifications.