Santosh M Kalekar
Foundry Operation & Development Ass Manager
Belgaum
Summary
Dynamic and results-driven Foundry Professional with over 14 years of comprehensive experience in managing end-to-end casting operations, including CI, SG Iron, and Gun Metal. Expertise in production planning, rejection control, ERP implementation, and cross-functional leadership consistently drives operational excellence and cost optimization. A strong track record of enhancing productivity and reducing defects, while effectively leading teams across multiple departments, demonstrates a commitment to continuous improvement. Proficient in addressing customer requirements, conducting audits, and implementing process enhancements to align with business objectives.
Overview
16
16
years of professional experience
10
10
Certifications
1
1
Language
Work History
Development Manager
REC Flow Technologies LLP (Foundry Division)
01.2011 - Current
- Leading end-to-end foundry operations including production, development, and quality coordination.
- Driving production planning and ensuring on-time order execution.
- Monitoring and controlling rejection trends for CI & DI materials.
- Managing complete Gun Metal casting process from order receipt to dispatch.
- Collaborating with ERP developer for system enhancements aligned with business needs.
- Handling IT infrastructure including system maintenance, backups, and troubleshooting.
- Leading pattern development from drawing stage to batch production.
- Ensuring process compliance and quality approvals at all stages.
- Resolving in-process quality issues using root cause analysis techniques.
- Representing operations in management discussions and customer interactions.
- Recruiting, training, and developing manpower across departments.
- Coordinating between core shop, melting, moulding, and finishing teams.
Production Supervisor
Belgaum Ferocast
01.2010 - 01.2011
- Supervised shop floor production activities ensuring adherence to quality and safety standards.
- Achieved production targets through effective manpower and resource utilization.
- Maintained process discipline and coordinated with teams for smooth operations.
Education
Diploma - Mechanical Engineering
Skills
Technical Skills:
Implementation of ERP systems
Experience with NX software
Experience with casting simulation techniques
Hardware and network support
Hands-on skill application
Production scheduling
Quality Management Systems
Process Optimization & Cost Reduction
Root Cause Analysis & Problem Solving
Team Leadership & Workforce Development
Customer Handling & Audit Management
New employee & Staff training
Problem-solving approach
Certification
Internal Auditor – ISO 9001:2015 (QMS)
Timeline
AI & Automation
03-2024
Internal Auditor – ISO 9001:2015 (QMS)
11-2023
Sustainable Development of Industries Through Industry 4.0 Application
12-2022
Foundry Costing & Process Optimization
08-2022
Government of Karnataka Department of Factories, Boilers, Industrial Safety & Health
05-2019
Internal Auditor – ISO 9001:2015 (QMS)
10-2017
Lean Manufacturing & process Improvement
01-2016
Production optimization & maintenance of disa ARPA & TM Mixer
02-2015
Development Manager
REC Flow Technologies LLP (Foundry Division)
01.2011 - Current
Production Supervisor
Belgaum Ferocast
01.2010 - 01.2011
Diploma - Mechanical Engineering
DECLARATION
I hereby declare that the above information is true and correct to the best of my knowledge. Date: Place: Santosh M Kalekar
KEY ACHIEVEMENTS
- Successfully managed complete Gun Metal production lifecycle independently.
- Reduced rejection through effective process control and root cause analysis.
- Played key role in ERP system customization improving operational tracking.
- Developed and streamlined pattern development process.
- Trained and developed multiple supervisors and operators across departments.