Shell Removal Operator LPCT 841

General Job Processes

Take responsibility for and demonstrate safe work practices;
Verify lot and part identification including piece count;
Move and deliver parts to other cleaning operations;
Train other operators in job accountabilities.

Knockout Process

Knock off shell material with pneumatic, mounted and/or hand-held hammers;
Remove exothermic material, insulation, and wire from part;
Use torch to remove tundishes and downsprus.

Gritblast Process

• Load part onto fixture to ensure even removal of shell materials;
  Set appropriate time to gritblast part;
  Monitor machine operations;
  Remove wire and excess shot from part.

Waterblast Process

• Place parts on table or manipulator in waterblast cabinet;
  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;
  Visually inspect parts for foreign materials.

Shotblast Process

• Load castings into shotblast cabinet;
  Operate shotblast machine from outside cabinet by foot control or from inside walk-in cabinets by hand control;
  Shotblast parts in cabinet by directing handheld nozzles;
  Visually inspect parts for cleanliness during and after shotblast operation and mark parts for defects;
  Operate rotoblast and/or tumbleblast machines.

Leach Tank / Chemical Bath Process

• Prepare chemical baths to necessary specifications;
  Take acid bath samples to lab and check lab results;
  Calculate etch rate using standard formula and adjust alkaline baths if out of compliance;
  Chemically clean and rinse parts and hand etch as needed;
  Use alkaline baths, cold etch baths, and/or hot water washes to rinse parts;
  Check and monitor temperatures of tanks and drying ovens;
  Maintain chemical bath lines;
  Clean tanks and remove sludge;
  Neutralize any hazardous materials.

Safety

• Adhere to plant and department safety rules;
  Safely operates all equipment and tools;
  Identify and report safety problems;
  Conduct and/or participate in safety audits;
  Work with hazardous waste as needed.

Maintenance and Cleaning

• Perform minor maintenance and repair of equipment including changing hoses and nozzles, filters, checking oil levels, etc.;
  Clean work area, including proper cleanup and disposal of ceramic shell material;
  Check, charge and change batteries on forklift.

Other Accountabilities

• Meet all production and quality standards;
  Complete logs and records;
  Perform other tasks as directed.

Essential Equipment, Vehicles, Machinery And/Or Tools Used

• Forklift;
  Waterblast machine;
  Sandblast Cabinets / Booths;
  Shotblast Cabinets / Booths;
  Surface Finishing Equipment (DC and SSBO);
  Air hose;
  Chip gun;
  Lifting Devices including hoists, fixtures, chains and straps;
  Water hose;
  Basic hand tools (e.g. hammers, wrenches, screwdrivers, pliers, saws, wire cutters, etc.);
  Brooms, shovels, and buckets;
  Hoppers.

Qualifications

• Ability to rotate through all 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;
  Ability to wear PAPR, respirator, purified air helmet, protective coveralls, safety glasses, safety goggles, double hearing protection, and safety shoes with metatarsal protection.