Casting - Chemical Process Operator 3rd shift

SUMMARY

Proficient operating Equiax (Eqx), Directionally Solidified (DS) and Single Crystal (SX) vacuum furnaces to produce high quality investment castings as required per customer specifications. Collaborates to develop new casting processes based on engineering requirements and customer specifications. Troubleshoots process variations and anomalies to provide technical support to manufacturing departments.  Additionally, ensures on time production of investment castings to meet the highest quality standards at the lowest possible cost.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Include the following (Other duties may be assigned):

• Utilizes process knowledge, basic engineering principles, previous experience, and creativity, as necessary to help develop and improve casting processes that result in the production of quality castings that conform to customer specifications and desired lead times.

• Reads and understands engineering procedures to ensure adherence and compliance to approved process.

• Participates in plant initiatives to support the reduction of scrap and overall casting cost.  Initiatives include but not limited to daily production meetings, NPI review meetings and participation in cost improvement teams.

• Performs typical duties of a vacuum caster (Alloy loading, liner loading/unloading, thermocouple repair and replacement, chill plate cleaning, monitor casting cycle, review cycle trend, etc.)

• Completes start-up procedure for Eqx, DS and SX vacuum furnaces (Checks oil levels on pumps, blowers, horizontal feeder, verifies equipment operability, etc. and fills as required ).

• Verifies correct alloy and master heat are used in accordance with the requirements of each work order.

• Ensures correct mold is pulled from preheat oven and it is properly positioned into furnace lower chamber.

• Reports 12-15 minutes prior to shift start to get daily status of furnace /jobs from previous shift prior to daily T1 meeting in the Fishbowl meeting room. ( Paid time , for oncoming caster and no leaving early for off going caster )

• Performs equipment pre-checks (Grounding check, Leak-Up Rate, etc.) and completes Pre-Flight Checklist, as required per department.

• Proficient operating foundry manufacturing equipment (Alloy Prep Equipment, Pre-Heat and Vacuum Furnace).

• Completes required manufacturing documentation of department (Melt Logs, Daily Furnace Checklists, Mercury Logs, etc.)

• Makes metals tags to identify poured molds.

• Programs withdraw speeds.

• Operates Eqx, DS and SX vacuum casting furnaces to pour alloy into molds per engineering specifications and customer requirements.

• Collaborates to improve ergonomics and safety conditions of assigned areas.

• Wears all required personal protective equipment and ensures personal protective equipment is available and in good condition.

• Supports training of new operators and process changes.

• Reports out molds not in compliance with engineering specifications (Red tag molds).

• Identify opportunities to reduce scrap and process variation.

• Maintains a clean, orderly and safe work area. ( All 6S activities )

• Other reasonable requested duties.

QUALIFICATIONS 

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

            EDUCATION and/or EXPERIENCE

• High school diploma or general education degree (GED) or equivalent in life experience.
• Previous foundry related experience or college degree is a plus.

            LANGUAGE SKILLS

• Ability to read, analyze and understand engineering procedures and customer specifications.
• Ability to read and interpret documents such as safety rules, operating and maintenance instructions and general standard practices.
• Ability to write reports and business correspondence.
• Ability to effectively present information and respond to questions from supervisors / managers, clients, customers and the general public.

            MATHEMATICAL SKILLS

• Ability to add, subtract, multiply, and divide in all units of measure using whole numbers, and decimals.
• Ability to apply concepts such as fractions, percentages, ratios and proportions to practical situations.

            REASONING ABILITY

• Ability to define problems, collect data, establish facts and draw valid conclusions.

            OTHER SKILLS AND ABILITIES

• Must be computer literate
• Demonstrated troubleshooting skills and techniques.
• Ability to operate or be trained to operate a fork lift truck.
• Organized, with a solid understanding of 5S methodology.

            OTHER QUALIFICATIONS

• In accordance with ITAR regulations, position requires US citizen or Permanent Resident status.

CASTING MAINTENANCE TECHNICIAN

• Casters that have been selected for their technical knowledge and mechanical abilities will be involved with small repairs, adjustments etc. to assist maintenance in completing required work on furnaces, etc.

PHYSICAL DEMANDS 

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is regularly required to stand. The employee frequently is required to use hands to finger, handle, or feel objects, tools, or controls; reach with hands and arms; and talk or hear. The employee is occasionally required to walk; sit; climb or balance; and stoop, kneel, crouch, or crawl. The employee must regularly lift and/or move up to 10 pounds, frequently lift and/or move up to 25 pounds, and occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus.

WORK ENVIRONMENT 

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job .

While performing the duties of this job, the employee frequently works near moving mechanical parts. The employee is occasionally exposed to wet and/or humid conditions, fumes or airborne particles, and vibration. The noise level in the work environment varies from quiet in office areas to very loud in the manufacturing environment.  However, the eight to twelve hour time weighted exposure to noise averages less than 85 dBA.

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