CASTER/MOLD HANDLER

JOB SUMMARY

Responsible for operation of casting unit; melts and pours into ceramic molds using induction or vacuum induction furnaces according to critical, prescribed written instructions and procedures.  Caster/Mold Handler may not move for two (2) years unless movement is a promotion within the department.

Works under general supervision and the direction of a caster to remove molds from the preheat furnace, properly position in a timely manner for casting, perform wrap application, dewaxing, repair, and mold inspect and perform all post-cast operations specified.

Works with a mold-handler and at times performs the mold-handling operation to preheat ceramic molds and melt alloy to pour into the preheated molds.

ESSENTIAL FUNCTIONS

• Using Computers (entering information, etc.)
• Must be able to read and interpret Product Criteria (PC) and Activity Instructions (AI).
• Must be able to function as a member of a team and be able to work under general supervision.
• Must be able to maintain expected quality levels.
• Comply with all site required policies and procedures including but not limited to:  EHS, Quality, Code of Conduct and the Wichita Falls Employee Handbook.

 

 1.    Read all available instructions and assist caster to cast molds in accordance with established techniques and specific instructions on the Product Criteria, Mold Sheets or Activity Instructions.   
2.    Requires concentration for short periods of time when assisting in the acquisition of the proper alloy, checks preheat temperatures, handles the molds from the preheat furnace and again after casting, and accomplishes all specific post-cast operations (Hexamine, mold stripping, exothermic application, and vermiculite encapsulation).   
3.    Particularly responsible for proper mold positioning, lower chamber cleaning, and the control of variables affecting solidification and mold cooling.   
4.    Moves empty, hot furnace trays, changes and cleans door gaskets, performs heavy housekeeping required in department, and assists in minor equipment maintenance.   
5.    Notifies caster of any torn wraps, bumped or leaking molds.   
6.    Periodically required to load ovens.   
7.    Keep updated on new methods on improvements.   
8.    Must follow all safety practices and procedures.   
9.    Locates scheduled work, moves trucks to proper workstation.   
10.    Ensures molds are kept clean in each area.   
11.    Seals molds at dewax or mold inspection with either ceramic disk or rubber cap.   
12.    Monitors operation of equipment and temperature controls.   
13.    Must follow Work Instructions and Activity Instructions that govern each job task.   
14.    Inspects and repairs molds.   
15.    Prepares solutions and maintains supplies.   
16.    Cuts required kaowool and rollboard.   
17.    Wraps molds per Process Releases/Product Criteria.   
18.    Must be able to operate the required piece of mobile equipment for this area.    
19.    Machines and work area are to be kept clean and in orderly condition.  Supervisor is to be notified immediately of equipment or machinery malfunctions.   
20.    Completes necessary paperwork as required.   
21.    Verifies mold counts and paperwork correctness on lot travelers, or serial numbers at each operation.   
22.    Loads molds in preheat oven.   
23.    Performs other duties as required.   
24.    Complies with all EHS rules related to the work environment.   
•    Works Overtime when needed.

 

          

PHYSICAL DEMANDS/EQUIPMENT USED

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.

•  Employee is required to execute the following:
• Considerable physical effort is required when loading alloy.
• Reach for items nearby, far, and overhead.
• Fine manipulation, using a keyboard and mouse.
• Lifting and carrying to the waist-to-chest high level, floor to waist and chest to overhead.
• Gripping Pinching and Handling.
• Climb stairs and ladders.
• Crawl, squat, balance, and sustain bending.
• Finger Press and tolerate hand/arm vibration.
• Be able to carry with one hand.
• Pushing, pulling, and twisting.
• Be able to carry items with two hands.
• Moderate lifting from 25lbs to 50lbs
• Requires almost constant standing and sufficient strength to lift, handle and transport heavy, hot molds, and hot molds containing molten alloy
• Must pass Jaeger 2 vision test annually for depth perception when pouring alloy and setting mold position.

Training:

• Three to six months on-the-job training required for satisfactory job proficiency.
• Training Folder
• Molten Material
• Combustion Systems
• Hazardous energy sources (LTV)
• Electrical

1. Work Environment: (Chemical and Physical Exposure):

• Extreme care must be taken because of exposure to extremely high temperatures for short periods of time.
• Exposure to dust and fumes from the casting process.
• Occasional exposure to uncontained molten metal sprays and solid metal chips from chamber cleaning.
• Requires wearing dust mask during certain procedures.
• Exposure to Nickel and RCF