Roles and Responsibilities of a Costing Assistant – Aluminium Sand Casting Factory
1. Cost Estimation
Prepare cost estimates for new aluminium sand casting components based on customer drawings and specifications.
Calculate material, process, machining, and finishing costs.
Estimate moulding, melting, fettling, machining, heat treatment, and inspection costs.
Support the quotation team by providing accurate cost sheets.
2. Raw Material Costing
Calculate aluminium alloy consumption per casting.
Consider melting losses, gating and riser weight, and yield percentage.
Monitor aluminium ingot, scrap, and alloying element prices.
Update material cost databases periodically.
3. Process Cost Analysis
Calculate process-wise costs including:
Sand moulding
Core making
Melting
Pouring
Shakeout
Fettling
Heat treatment
Machining
Surface finishing
Packing
Identify major cost contributors and recommend cost-saving opportunities.
4. Labour Cost Calculation
Estimate direct labour hours for each manufacturing operation.
Calculate labour costs based on standard rates.
Compare standard labour costs with actual production data.
5. Machine Costing
Calculate machine hour rates for:
Melting furnace
Sand mixer
Core shooter
Shot blasting
CNC machines
Drilling and tapping machines
Include electricity, maintenance, depreciation, and operator costs.
6. BOM (Bill of Materials) Preparation
Prepare and maintain Bills of Materials for all products.
Update BOMs based on engineering changes.
Verify material quantities with design and production departments.
7. Cost Sheet Preparation
Prepare detailed product cost sheets including:
Raw material
Consumables
Labour
Machine cost
Tooling cost
Overheads
Packing
Transportation (if applicable)
Profit margin
Maintain historical costing records.
8. Production Data Collection
Collect production data from the shop floor.
Record cycle times and process efficiencies.
Monitor casting yield and rejection rates.
Analyze production losses affecting product cost.
9. Rejection and Scrap Cost Analysis
Calculate the cost impact of casting rejections.
Monitor scrap generation and recovery.
Identify recurring causes of rejection affecting profitability.
10. Inventory Cost Monitoring
Monitor inventory valuation of:
Aluminium ingots
Return scrap
Sand
Chemicals
Consumables
Coordinate with stores and accounts for inventory reconciliation.
11. Vendor Cost Comparison
Compare quotations from suppliers.
Analyze purchased component costs.
Support procurement in vendor selection based on cost competitiveness.
12. Cost Reduction Activities
Identify opportunities for:
Yield improvement
Scrap reduction
Energy savings
Process optimization
Material substitution
Assist in implementing cost-saving initiatives.
13. Coordination
Coordinate with:
Production
Design
Purchase
Quality
Sales
Finance
Gather necessary information for accurate costing.
14. Reporting
Prepare reports on:
Product-wise costing
Monthly cost analysis
Material price variations
Cost variances
Profitability analysis
Cost reduction initiatives
Key Skills Required
Maintain master data for materials, routing, and standard costs.
Generate costing and variance reports.
Knowledge of aluminium sand casting processes.
Understanding of costing principles and manufacturing economics.
Ability to read engineering drawings.
Knowledge of Bills of Materials (BOM) and process routing.
Strong analytical and numerical skills.
Proficiency in Microsoft Excel (Pivot Tables, VLOOKUP/XLOOKUP, formulas, charts).
Familiarity with ERP software.
Good communication and coordination skills.
Attention to detail and accuracy.
Educational Qualification
B.Com / BBA / MBA (Finance) for costing-focused roles, or
Diploma/B.E. in Mechanical, Production, or Metallurgical Engineering for technical costing roles.
Additional certification in Cost Accounting or ERP systems is advantageous.
Key Performance Indicators (KPIs)
Accuracy of cost estimates.
Quotation turnaround time.
Standard vs. actual cost variance.
Material yield improvement.
Reduction in scrap and rejection costs.
Timely preparation of BOMs and cost sheets.
Accuracy of ERP costing data.
Contribution to cost reduction initiatives.
On-time submission of costing reports.
Support for achieving target product margins.
Pay: ₹30,000.00 - ₹35,000.00 per month
Benefits:
Work Location: In person
