Shell Removal Operator LPCT 841

About the Role

This position requires Operators to rotate through all shell removal and cleaning processes as dictated by product flow and customer throughput requirements. The role involves removing shell material, core material, and scale from castings and their gating systems using a variety of processes to ensure efficiency in product flow, cost of operation, and meeting customer demands.

Responsibilities

• General Job Processes:
  • Demonstrate and take responsibility for 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 parts.
  • Use a torch to remove tundishes and downsprus.
• Gritblast Process:
  • Load parts onto fixtures to ensure even removal of shell materials.
  • Set appropriate time to gritblast parts.
  • Monitor machine operations.
  • Remove wire and excess shot from parts.
• Waterblast Process:
  • Place parts on a table or manipulator in the waterblast cabinet.
  • Clean parts using automated and/or manual controls to direct the water jet.
  • Visually inspect parts for foreign materials.
• Shotblast Process:
  • Load castings into the shotblast cabinet.
  • Operate shotblast machines from outside or inside the cabinet.
  • Direct handheld nozzles to shotblast parts.
  • Visually inspect parts for cleanliness and mark defects.
  • Operate rotoblast and/or tumbleblast machines.
• Leach Tank / Chemical Bath Process:
  • Prepare chemical baths to necessary specifications.
  • Take acid bath samples to the lab and check results.
  • Calculate etch rate and adjust alkaline baths if out of compliance.
  • Chemically clean, rinse, and hand etch parts 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.
  • Wear protective gear when working with chemicals.
  • Clean tanks and remove sludge.
  • Neutralize hazardous materials.
• Safety:
  • Adhere to plant and department safety rules.
  • Safely operate 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 (e.g., changing hoses, nozzles, filters, checking oil levels).
  • Clean work area, including proper cleanup and disposal of ceramic shell material.
  • Check, charge, and change batteries on forklifts.
• Additional Requirements:
  • Meet all production and quality standards.
  • Complete logs and records.
  • Perform other tasks as directed.

Equipment Used

• Forklift
• Waterblast machine
• Sandblast Cabinets / Booths
• Shotblast Cabinets / Booths
• Surface Finishing Equipment (DC and SSBO)
• Air hose
• Chip gun
• Lifting Devices (hoists, fixtures, chains, and straps)
• Water hose
• Basic hand tools (hammers, wrenches, screwdrivers, pliers, saws, wire cutters, etc.)
• Brooms, shovels, and buckets
• Hoppers
• Protective gear (PAPR, respirator, purified air helmet, protective coveralls, safety glasses, safety goggles, double hearing protection, safety shoes with metatarsal protection)

Training

• Basic Skills training.
• On-the-job training provided.
• PCC's Forklift Driving Safety Certification Training (must be completed).
• Hazardous waste management training (may be required).
• Basic Chemistry Course (may be required).
• Visual Inspection Class (may be required).
• Radiation Safety Training (as required).
• Other training as required by Team and/or location.

Qualifications

• Ability to rotate through all cleaning and 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).
• Effective verbal and written communication skills.
• Physical ability to perform job functions, including lifting, carrying, and/or maneuvering objects weighing 30 to 50 pounds.
• Ability to work in difficult conditions (e.g., noise, dust, chemicals, temperature extremes) for extended periods.
• Ability to stand for the duration of the entire scheduled work shift.
• Ability to wear required protective gear (PAPR, respirator, purified air helmet, protective coveralls, safety glasses, safety goggles, double hearing protection, and safety shoes with metatarsal protection).