DC Casting Operator

SUMMARY

Responsible for casting molten metal products from secondary aluminum in different shapes, alloys and sizes (billet and slab ingot) according to production standards by operating different systems of a casting production area.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Reviews casting parameters and prepares tooling and other equipment for production according to specifications

Inspects casting tooling and equipment reports and discrepancies

Prepares runners, troughs, and surge boxes, and makes sure equipment such as tools and filters are in good condition and properly coated

Ensures that he and the casting crew is attired with the appropriate protective personal equipment before starting the cast

Sets up casting-tooling such as water tables, molds and stools according to work instructions

Ensures hand tools are available properly coated, pre heated and serviceable prior to the start of each cast

Sets casting equipment with established parameters prior and during the casting process

Directs casting helpers to help maintain correct casting parameters of production during the casting process

Helps correct poor performance and improve casting processes through participation in group discussions or with individual ideas or suggestions

Responsible for cleaning and maintenance of the casting area including equipment, tooling, and fixtures before and after each cast according to work instructions

.Checks water quality and level in casting pit.

Checks level and quantity of metal in furnace and controls panels to obtain adequate furnace and flux unit temperature prior to casting

Checks condition of furnace tap outs, to avoid metal leaks and takes action to correct problems or malfunctions and makes sure temperature is correct.

Check flux units for proper operation, and that they are covered to prevent dross floating.

Taps furnace to allow flow of metal, controls flow rate and corrects discrepancies as necessary.

Monitors flow of water into molds.

Monitors lubrication system and elevator speed.

Obtains metal samples at proper intervals of casting process.

Checks condition of overhead crane and make sure lifting equipment is in good condition.

Installs and remove casting tables using overhead crane

Inspects and removes product from casting pit using overhead crane

Maintains good housekeeping by properly storing material, equipment and tools at the end of the shift.

Performs other duties as assigned by Management.

SHIFT FOR THIS POSITION: FLOATING SHIFT

Must be able to perform each duty according to minimum standards of production, quality and safety as specified by standard operating procedure.

SKILLS AND ABILITIES

Ability to read and interpret documents such as safety rules, operating and maintenance instructions, and procedure manuals. Ability to write routine reports and correspondence. Ability to speak effectively before groups of customers or employees of organization. Ability to use word processing and spreadsheet software.

Ability to add, subtract, multiply, and divide in all units of measure, using whole numbers, common fractions, and decimals. Ability to compute rate, ratio, and percent and to draw and interpret bar graphs.

Ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form. Ability to deal with problems involving several concrete variables in standardized situations.

Wide variety of routine tasks that involve some choice of action within limits.

PHYSICAL DEMANDS
While performing normal duties, the employee is regularly required to stand, to walk, and use hands frequently. The employee must occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include distance vision, color vision, peripheral vision, and depth perception to operate equipment, read control gauges, and identify plant color code system. Reasonable accommodations will be made for individuals with disabilities in accordance to legal requirements.

WORK ENVIRONMENT
While performing normal duties, the employee is regularly exposed to fumes, airborne particles and extreme heat. The employee is frequently exposed to moving mechanical parts, and occasionally exposed to wet and/or humid conditions, outside weather conditions, and vibration. The noise level in the work environment requires hearing protection. Reasonable accommodations will be made for individuals with disabilities in accordance to legal requirements.