Foundry Operator; 1st Shift

Under general supervision, melts various alloys in preparation for pouring into molds in accordance with quality standards. Ensures that documentation and molds are correctly matched to alloy and paperwork. To preheat shell molds to proper temperature and place molds in sand bed in proper manner to receive molten alloy according to specifications.

• Follow established housekeeping and safety practices to maintain the quality of the work environment under general supervision.
• Follows set process control procedures for melting and deoxidizing.
• Regulates burnout furnace and molten metal temperatures.
• Follows instructions on a schedule of molds to be cast.
• Checks with spectrograph for proper alloy and heat number of each alloy.
• Pours test material molds as required.
• Assists with keeping an accurate metal inventory.
• Understands and follows the Divisional Quality Policy, be able to identify the location of the QCP’s, Quality System Manual, and OPC’s. Must remain proficient in all skills learned in previous department levels.
• Show the ability to take necessary steps to anticipate problems or prevent any reoccurrence of production problems.
• Show the ability to communicate and consult with lead and supervisory personnel.
• Display a willingness to learn on the job and take vocational or educational courses when offered.
• Proficient in using the on-line computer system as required in the job and identified in their procedures to perform assigned tasks.
• Demonstrate skillfulness in relining and general maintenance of the melting furnaces. Must demonstrate the ability to replace and repair the coil grouting of any of the induction furnaces. Must exhibit good judgment in determining the end of the work life of the furnace linings.
• Understands the basic workings of the inductotherm water pumping system and must demonstrate the correct operation of the cooling pumps under all circumstances.
• Demonstrate calmness and good judgment under adverse conditions. Must show knowledge of proper courses or action in varied emergency situations, real or hypothetical.
• Ensure at all times that metal alloys, revert metals, spills and skulls are identified and stored as required.
• Demonstrate knowledge of start-up and shut down procedures for the mold burn-out ovens. Must know all related safety aspects of the burn-out ovens.
• Clearly and in proper detail, perform all the record keeping duties assigned.
• Demonstrates knowledge of deoxidizing practices.
• Correctly and accurately maintain control of melt temperature.
• Pours representative test material for air melt alloys.
• Inspect shell molds for surface distortion and imperfections such as air traps, dirt inside mold, cracks, breaks, excess flash, and porous condition.
• Performs all other duties assigned.

• A variety of Heating Ovens and Vacuum Melting Furnaces.
• Lifting devices (Lift tables, Cranes, Forklifts, etc.).
• Various hand tools, Knives, Measuring devices, Ingot Saws, Acetylene Torch.

• Experience and/or training are included in considerations.
• Ability to communicate effectively in English, both verbally and in writing, read, follow and interpret instructions on technique cards, code sheets as well as other verbal or written instructions. Normally acquired by completing high school.
• Ability to perform basic mathematical calculations.
• Ability to use simple to moderately complex measuring devices and fixtures.
• Physical ability to perform the essential job functions.