VAR Melt Operator Level I - IV

Job Summary

Efficiently operate and maintain the VAR Furnace(s) and associated pre-melt and post‑melt equipment to meet productivity and quality targets. Interpret and respond to the needs of the equipment. Perform skilled maintenance, set‑up and troubleshooting functions as required.

• Follow standard manufacturing and operating procedures.
• Perform pre-operative checks prior to and during pump down cycle using the pre‑pump and startup checklist.
• Set up and operate furnace(s) for melting, including inspecting and preparing electrodes, welding stubs, cleaning and maintaining crucibles and base plates, loading electrodes, operating the stub welder, vacuum systems, furnace controls and instrumentation.
• Conduct melting, cooling, unloading, identifying and weighing ingots; drill and chamfer ingots; use band saw to cut stubs and electrodes.
• Interpret video monitors, gauges, meters while operating the furnaces.
• Maintain operating records, logs, material and maintenance needed lists.
• Perform leak‑up rate tests, operate leak detectors and clean furnaces and crucibles during maintenance cycles, replacing damaged components.
• Use hand and power tools as directed and perform maintenance to keep furnace(s) and auxiliary equipment (electrical, electronic, vacuum, hydraulic, pneumatic, cooling systems) in good operating condition.

Support other departments as needed per production demands.

• Attendance/Punctuality: consistently at work, on time, and ensures responsibilities are covered when absent.
• Communication/Interpersonal
  
  Skills:
  
  solves conflicts, listens without interrupting, maintains a positive attitude, and communicates effectively with co‑workers and outside contacts.
• Dependability: follows instructions, takes responsibility, keeps commitments, and works long hours when necessary.
• Ethics and Integrity: treats people with respect, keeps commitments, works with integrity, and upholds organizational values.
• Initiative: volunteers, undertakes self‑development activities, seeks increased responsibilities, and offers help when needed.
• Quality: demonstrates accuracy, thoroughness, and seeks ways to improve and promote quality.
• Quantity: meets productivity standards, completes work in a timely manner, and works quickly and safely.
• Safety & Environmental: observes safety regulations, uses personal protection equipment, maintains an organized area, and reports unsafe conditions.
• Teamwork: balances team and individual responsibilities, builds morale, and supports teammates’ success.
• Language Skill: reads and interprets documents, writes routine reports, and speaks effectively before groups.
• Mathematical
  
  Skills:
  
  performs addition, subtraction, multiplication, division, and basic calculations, and interprets bar graphs.
• Reasoning Ability: solves practical problems with limited standardization and interprets instructions in various formats.

• High school diploma/GED or equivalent (required). Trade school or additional training preferred.
• Three years working experience in a relevant environment preferred.
• Must be mechanically inclined, possess basic math skills, follow instructions, work in a group, work any schedule including holidays and weekends, lift up to 35 pounds, work with heavy rigging, piping, forklift and crane operations (highly preferred), think quickly and act decisively, wear a respirator, work in confined spaces, and have a strong learning aptitude.

• Melt Operator I:
  High school diploma/GED or equivalent; two‑year technical degree or certificate (Electronic, Mechanical or Welding) or 18 months of demonstrated skills and completed skills testing.
• Melt Operator II
  :
  Meets Mo I requirements plus at least 3 years of melt experience and evidence of exemplary performance.
• Melt Operator III
  :
  Meets Mo II requirements plus at least 5 years of melt experience, evidence of exemplary performance, and successful fill‑in lead experience.
• Melt Operator IV
  :
  Meets Mo III requirements plus at least 8 years of melt experience, completed Lead Operator OJT and certification, and consistently performs at an exemplary level.

• Frequently required to talk, hear, stand, walk, sit, use hands, reach, stoop, kneel, crouch, or crawl.
• Occasionally lift or move up to 35 pounds.
• Requires close, color, peripheral, and depth vision.

The typical work environment is a mill or manufacturing setting with moderate noise. Employees may be exposed to moving mechanical parts, elevated or precarious locations, fumes or airborne particles, toxic or caustic chemicals, and risk of electrical shock.