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Mold Machine Operator

Location : Palmer MA
Job Type : Direct
Start Date : 08/12/2019
Hours : Full Time
Travel : No
Relocation : No

Job Description :

To remove molds from pouring floor and bring to knockout area where they can be dismantled to the casting part.




  • Startup Knockout area equipment per NB Knockout Area Equipment Startup SOP.




  • Move molds from pouring floor to knockout holding area.




  • After Move Time (-15 min./+ 60 min. or as space allows) has elapsed, record Part Number on Form NB 8.2.3-06 Knockout Department Data Entry.




  • Unclamp molds so as not to bend pipe clamps when moving mold.




  • Use fork truck to move mold from Pouring Floor to KO holding area in front of the outside overhead door.




  • Stage molds for knockout




  • Use Pour Time recorded on NB Melt Data Collection Form, Form # NB 7.5.3-01 and Wait Time on Process Sheet to determine order in which KO WIP will be processed.  




  • Use fork truck to stage KO WIP in KO holding area.




  • Before end of shift, notify NB Foundry Supervisor of any molds that will not be knocked out before end of shift.




  • Move Mold to deck staging area




  • Use fork truck to move next mold designated for SO from KO holding area to SO Deck staging area.




  • In the absence of WIP, molds may be moved directly from Pouring Floor or KO holding area to SO Deck staging area after required Time(s) have elapsed.




  • Remove items from mold before Knockout as specified on Process Sheet.  




  • Use a hammer to remove locators and the crane to remove vent pipes from mold in order to prevent damage to casting or magnetic belt.   For efficiency and good housekeeping, leave handling hooks in mold.




  • Remove spilled aluminum from mold and place in riddle located in KO.




  • Prepare shake out deck




 




  • Using packed sand, loose sand, “dry” NB Core sand, or a combination thereof, ensure there is an adequate bed of sand on shaker deck to prevent casting from coming in contact with SO deck. 




  • Visually inspect SO deck for items from previous job, such as chills, hooks, rods, flashing, locators, etc.  Remove items from SO deck.




  • After Wait Time (-0 hrs. / +ASAP) has elapsed, move mold from staging area to SO deck using handling equipment specified on KO Process Sheet.  




  • Record KO Start Time on Form NB 8.2.3-06, Knockout Department Data Entry.




  • Start the shakeout deck and conveyor per NB Knockout Area Equipment Startup SOP to knock out the casting from the mold.




  • Remove chills during Knockout




  • Remove other items during Knockout as specified on Process Sheet.




  • Remove remaining sand from casting using shakeout deck, painter’s tool, hammer, and/or air chisel.  




  • Record serial number on Form NB 8.2.3-06, Knockout Department Data Entry.




  • Use crane to lift casting from SO Deck to SO staging area.   Do not suspend casting over Cutoff skid.




  • Use painter’s tool to remove riser sleeve(s) from suspended casting.  




  • Discard sleeve(s) in trash can.  




  • It is important to keep riser sleeves from going through the KO area equipment because fibers can block sand system screens.    




  • Use crane to place casting on Cutoff skid as specified on KO Process Sheet.  Correct orientation is important for safety and efficiency at Cutoff operation.    




  • Use fork truck to move casting from KO staging area to Cutoff operation.




  • Store items removed from mold in designated areas:




  • Vent Pipes:  Vent Pipe tote




  • Locators:  Mold handling hook cart




  • Hard Flask:  Return to Molding department at end of job




  • Pop-off Flask:  Return to Molding department at end of job




  • Frame:  Return to Molding department at end of job




  • Rods, large:  Rod barrel 




  • Rods, small:  Bucket for cores




  • Core hooks:  Bucket for cores




  • Handling Hooks:  Hook cart




  • Chills:  Chill tote




  • Vent Rope:  Trash




  • Periodically throughout the shift, clean all spilled sand from knockout area.




  • At start of shift, remove chills in hopper.  Place chills in chill tote.




  • At start of shift, remove all chills, hooks, rods, vent rope, metal, etc. from mechanical reclaimer. 




  • At start of shift, remove access panel and clean vent rope and metal from lower portion of mechanical reclaimer.  Discard in wheelbarrow.  When full, dump in Bobcat bucket and dispose of in spent sand area behind Green Sand foundry.




  • Periodically throughout the shift, visually inspect quantity of reject sand that collects in the drum.  The drum should not have to be emptied daily.  If it does, clean the upper mechanical reclaimer screen.  Otherwise, empty drum into Bobcat bucket and dispose of in spent sand area behind Green Sand foundry.  




  • Once per shift, visually inspect upper mechanical reclaimer screen.   Remove riser sleeve debris.  




  • Periodically throughout the shift, visually inspect the sand level in the bottom of the pit.  




  • Clear sand from the bottom of the pit to prevent the skip hoist from overflowing.




  • Daily, visually inspect the transfer conveyor located in the pit below the shaker.




  • Remove or vacuum all sand from around the bearings.  




Required Qualifications :
 

















Competency:



To perform the job successfully, an individual should demonstrate the following competencies: Problem Solving - Identifies and resolves problems in a timely manner. Oral Communication - Listens and gets clarification. Team Work - Balances team and individual responsibilities. Adaptability - Adapts to changes in the work environment. Dependability - Follows instructions, responds to management direction.



Qualifications:



To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.


Education/Experience:
No specific education or certification is required, however, high school diploma or general education degree (GED); or one to three months related experience and/or training; or equivalent combination of education and experience is desired.


Language Ability:
Ability to read and write


Math Ability:
Ability to add and subtract


Reasoning Ability:
Ability to apply common sense understanding to carry out detailed but uninvolved written or oral instructions. Ability to deal with problems involving a few concrete variables in standardized situations.


Computer Skills:
To perform this job successfully, an individual should have knowledge of database software for reviewing work instructions.


Supervisory Responsibilities:
This job has no supervisory responsibilities.




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