Job Title: Shell Removal Specialist
This role involves working with various cleaning processes to remove shell material, core material, and scale from castings and their gating systems. The successful candidate will be able to rotate through all of the shell removal/cleaning processes as dictated by product flow and customer throughput requirements.
Key Responsibilities:
* To take responsibility for and demonstrate safe work practices;
* To verify lot and part identification including piece count;
* To move and deliver parts to other cleaning operations;
* To train other operators in job accountabilities.
The following are the key processes involved in this role:
Knockout Process:
* To knock off shell material with pneumatic, mounted and/or hand-held hammers;
* To remove exothermic material, insulation, and wire from part;
* To use torch to remove tundishes and downsprus.
Gritblast Process:
* To load part onto fixture to ensure even removal of shell materials;
* To set appropriate time to gritblast part;
* To monitor machine operations;
* To remove wire and excess shot from part.
Waterblast Process:
* To place parts on table or manipulator in waterblast cabinet;
* To clean parts with waterblast machine/equipment by using automated and/or manual controls (by hand and foot) to direct the water jet from outside the cabinet;
* To visually inspect parts for foreign materials.
Shotblast Process:
* To load castings into shotblast cabinet;
* To operate shotblast machine from outside cabinet by foot control or from inside walk-in cabinets by hand control;
* To shotblast parts in cabinet by directing handheld nozzles;
* To visually inspect parts for cleanliness during and after shotblast operation and mark parts for defects;
* To operate rotoblast and/or tumbleblast machines.
Leach Tank / Chemical Bath Process:
* To prepare chemical baths to necessary specifications;
* To take acid bath samples to lab and check lab results;
* To calculate etch rate using standard formula and adjust alkaline baths if out of compliance;
* To chemically clean and rinse parts and hand etch as needed;
* To use alkaline baths, cold etch baths, and/or hot water washes to rinse parts;
* To check and monitor temperatures of tanks and drying ovens;
* To maintain chemical bath lines;
* To wear protective gear when working with chemicals;
* To clean tanks and remove sludge;
* To neutralize any hazardous materials.
Additional Responsibilities:
* To adhere to plant and department safety rules;
* To safely operate all equipment and tools;
* To identify and report safety problems;
* To conduct and/or participate in safety audits;
* To work with hazardous waste as needed.
Requirements:
* Ability to rotate through all of the cleaning/shell removal processes;
* Cleaning and blasting skills, working knowledge of blasting machines, and knowledge of parts and gating systems;
* OR an equivalent combination of classroom training and work experience.
* Ability to work independently;
* Ability to follow instructions and read process sheets and routers;
* Ability to perform basic mathematical calculations (addition and subtraction);
* Ability to communicate effectively both verbally and in writing;
* Physical ability to perform the job functions;
* Ability to safely lift, carry and/or maneuver objects weighing thirty to fifty pounds;
* Ability to work in difficult working conditions which may include exposure to noise, dust, chemicals, temperature extremes and other elements for extended periods of time;
* Ability to stand for duration of the entire scheduled work shift.
Shell Removal Specialist