محمد فراز شايك

Melting & Refractory Operations
Leading the Melting and Refractory departments, overseeing a team
of over 80 personnel.
Melting shop is equipped with 24 MT (5 Nos) and 12 MT (2 Nos)
Induction Furnaces.
Expert in producing Ductile Iron grades through various techniques,
including George Fischer converter, Plunger treatment and Mg cored
wire injection process.
Resolved recurrent melting and refractory-related rejections through
process improvements and root cause analysis (RCA).
Achieved significant cost savings in the Bill of Materials (BOM) by
optimizing the charge mix through improved blend formulations.
Developed and implemented refractory replacement strategies,
resulting in improved hoppers uptime and reduced maintenance
cost.
Supervised ladle and hopper lining/conditioning operations to
ensure thermal integrity and reduce heat losses.
Standardized refractory usage practices, improving material
lifecycle and minimizing downtime.
Oversaw inspection and Quality verification of all incoming raw
materials including Pig Iron, scrap, alloys, and refractory materials
to ensure compliance with material specifications and melting
process standards.
Planning and Implementing CAPA (Corrective and Preventive Action)
initiatives.

Standardized in-process metallurgical control procedures to
maintain consistent melt quality.

Head of Induction Melting shop and Refractory division.

1. Equiped with 7 Induction Furnaces of 24MT(5no’s) and 12MT(2no’s).
2. Overseeing a team of 80 employees.
3. Rawmaterial selection and Inspection.
4. Employees KPI.
5. Cost Control / MT.
6. Power Consumption / MT.
7. Different types of Mg tretament to cast DI pipe, Fittings & Valves.
8. Refractory solutions for Melting and Casting Shop.

Oversaw operations of seven 25-MT induction furnaces.
Led melting shift operations for both Cold Mold and Hot Mold
processes.
Optimized furnace lining life and durability.
Reduced casting rejections by fine-tuning liquid metal chemistry.
Conducted charge-mix and mold-rejection analysis to identify and
eliminate root causes.
Collaborated closely with the mold shop to extend mold life per
single run.
Managed mold maintenance for both Cold Mold and Hot Mold
processes, including grinding and peening for the Cold Mold process
(DN 200-DN 1200).
Maintained SAP-based production, quality, and performance
reporting.

Automated green sand foundry, 72, 000 TPA grey iron components.

Operated 7 MT Induction Furnaces (5 Nos) and Press Pour Furnace.
Optimized chemistry and lining life for various cast iron grades.
Achieved production targets while minimizing process rejections.

210, 000 TPA ductile iron pipe plant (DN 100 to DN 1000).

Supervised 15 MT Induction Furnace operations (5 Nos).
Ensured stable liquid metal supply and chemistry optimization.
Enhanced lining practices to meet production efficiency goals.