Mission:
To safely operate Vacuum and Air casting processes in order to achieve plant quality and productivity goals. Continuously reduce the cost of the operation. To follow all process control procedures, standard operating procedures and technique card work instructions to insure the highest quality workmanship results.
Goals:
A. Develop cross-trained employees between all casting methods.
B. Apply flexibility in order to react customer orders with lower inventory.
C. Reward leadership and excellence in balance with business needs.
Principal Accountabilities:
1. Flexibility:
a. Willing to train, certify and work in any casting or metal prep function needed by the team.
b. Willing to work offshifts, weekend setup and floor work as required by rotation schedule.
c. Willing to work in multiple areas as required supporting daily casting schedules.
2. Preparation:
Objective: Prepare schedules, equipment, metal and molds prior to furnace operation.
Essential Job Functions:
A. Create/follow the written furnace plan.
B. Review casting schedules; communicate requirements with Supervisor and SF Leads.
C. Pours high quality castings using every method available.
D. Maintains a win score required for step per Job Progression Record (JPR).
E. Trains and certifies in each method within the time frame on the JPR.
F. Verifies that shell identification and metal assignments agree with casting schedule and technique card (both at pour and prior to shipping to the Cleaning Department).
G. Inspects and cleans shells in preparation for casting.
H. Identifies problems and opportunities and works with Supervisor to implement solutions.
I. Installs fixtures, insulation, filters, tundish and covers per technique card and SOP’s.
J. Loads and fires burnout furnaces, prepares maps and monitors cycles for proper operation and repair.
K. Change pots, leads, furnace oil as indicated for proper operation. Documents work performed in logs.
L. Checks vacuum levels, power supply, hydraulics and other furnace systems for proper operation.
M. Verifies weights and loads metal alloy charges into slip pots and crucibles.
3. Furnace Operation:
Objective: Efficiently melt and pour alloys into molds, according to all applicable procedures and work instructions.
Essential Job Functions:
A. Operates equipment including induction melting, hydraulic systems, doors, cranes and hoists.
B. Maintains process control parameters and records during melting and casting.
C. Performs and records calibrations.
D. Operates computer systems.
E. Transfers hot molds from burnout to casting furnaces.
F. May be required to train and certify to work with hazardous waste.
G. Document observations using PVN & Casting Feedback Forms.
4. Maintenance:
Objective: to maintain furnaces and support equipment to minimize downtime and cost while maximizing furnace output.
Essential Job Functions:
A. Cleans and/or has responsibility for regular furnace cleaning.
B. Maintain clean, organized work area.
C. Perform regular minor maintenance, calibrations and preventive maintenance on equipment.
D. Troubleshoot furnace problems and assist craftsmen on repairs.
E. Record equipment performance, identify changes and initiate corrections.
F. Maintain neat and accurate logs, production reports and process control records.
G. Provide work direction, training and working supervision to others as assigned.
H. Participate in audits, experiments and improvement teams. Promote teamwork.
I. Meet or exceed all safety, quality, production standards, training, certification and time on the job specified for each step placement within the job. These standards are complete in draft form but are subject to change based on best practices and business need for cross training and performance.
J. Promote safe practices, equipment and facilities by example and methods development.
Essential Job Functions:
1. Induction melting furnaces.
2. Vacuum and hydraulic pumps and controls.
3. Burnout furnaces.
4. Thermocouples.
5. Alloy verification equipment.
6. Forklift.
7. Hoists, cranes and Ergo-lift devices.
8. Basic hand tools (wrenches, chisels, etc).
9. Scales.
10. Data acquisition systems.
11. Welding and air-arc cutting equipment.
12. Pot pre-heaters and conditioners.
13. Fixtures and lifting devices.
14. Conveyors.
15. Pneumatic tools and chipping guns.
Training:
1. Training is provided on the job using supervised modular training, certification and outside coursework.
2. Certification in training modules and time on the job with acceptable performance is required for step advancement based on the most current Level Progression Record. Employees failing to meet Job Progression Record requirements will be reclassified at the appropriate step or returned to their previous job classification.
3. PCC Forklift Driving Safety Certification Training must be completed and kept up to date.
4. May be required to complete Hazardous Waste Management Training.
Qualifications:
1. Working knowledge of vacuum and air furnace operations as demonstrated by:
a. Currently perform duties of a furnace operator in Air/RO and Vacuum Casting.
b. Win score per Job Progression Record.
c. Certification as a Foundry Person or Heat Treat Operator if required by Supervisor.
d. An equivalent combination of experience or training.
2. Ability to read, understand and follow Technique Cards, Process Control procedures and Standard Operations procedures.
3. Ability to perform basic mathematical calculations with high accuracy (add, subtract, multiply, divide, percentages, graphing).
4. Ability to communicate effectively both verbally and in writing.
5. Ability to work independently with minimum supervision while contributing ideas and suggestions in a team environment.
6. Physical ability to perform the essential job functions in a hot environment.