Journeyman Molder / Molder - 3rd Shift

PRIMARY PURPOSE

Molders produce and assemble sand molds or related components used to manufacture aluminum castings.

ESSENTIAL DUTIES AND RESPONSIBILITIES

GENERAL

• Study work instructions to determine product specifications, tool requirements, and operational sequences.
• Record quantities of materials and finished products, requisitioning additional supplies, as necessary. 
• Operates and adjusts controls of heating equipment to cure, dry or bake filed core according to specifications.
• Position core(s) into lower sections of molds and reassemble molds for pouring.
• Move and position workpieces, such as mold sections, patterns, and bottom boards.
• Cut spouts, runner holes, and sprue holes into molds when necessary.
• Position patterns on equipment, materials, or workpieces.
• Maintain a clean and safe working environment.
• Complete daily inspections on tools and equipment, filling out forms when required to do so.
• Maintain housekeeping in the work area at the end of each shift.
• Maintain area per established 6S standards.
• Perform all other duties as assigned by supervisory or leadman personnel.

NO-BAKE (EAST, WEST, SOUTH)

• Place risers, down sprues, locater bars, filters, and chills into both the cope and drag core boxes prior to pouring sand per work instructions/
• Spray parting agents onto patterns and mold sections to facilitate removal of patterns from molds.
• Make sure core box is placed directly under sand dispenser.
• Use machine to start and stop the sand flow coming from mixer.
• Use a shovel to grab bad sand also known as dust that comes out of sand shoot first. (This is sand that will not harden.)
• When required, use riddle to break up sand before it fills the core box.
• Use compaction table to compact sand into core box pattern.
• Fill core box with sand using hands and tools to spread and pack down the sand. (Tucking)
• Once core box is filled and packed with sand, use compressed air to clean riser and sprue holes.
• Remove riser caps from the riser holes.
• Ram up core.
• Put a board “on top” of drag. (The bottom when flipped on machine)
• Cut spouts, runner holes, and sprue holes into molds.
• Move and position workpieces such as mold sections, patterns, and bottom boards, using cranes, or signal others to move workpieces.
• Place positioning rods into molds per work instructions.
• Assemble the mold per work instructions using paste. (Different pastes depending on job)
• Use a file other hand tools to fix any surface defects.

GREEN SAND

• Pick up roller from flatbed and place onto conveyor line.
• Prepare mold pattern with necessary filters and screens.
• Grab flask from flatbed and separate halves.
• Position top half of flask on table and set mold pattern (cope side face down) on top half.
• Place the remaining half of the flask on top of the pattern (drag side is face up).
• Position the mold under sand hopper and spray the pattern with part­ing agent.
• Pull lever to open sand hopper.
• Use riddle to break up large clumps of sand until pattern is covered.
• Fill the remainder of the flask with sand.
• Use bottom board, ramming tools, and/or pneumatic hammer to pack sand on either half of the mold.
• Flip the mold (leaving bottom board under drag) so the cope side is facing up and repeat sand filling process.  
• Remove cope half of the flask from pattern and set aside.
• Remove pattern from drag.
• Place necessary cores in the drag half.
• Make sure each half of the mold is in proper condition; pouring holes clear, no missing pattern chunks, etc.
• Use compressed air to clean off loose sand on the drag, cope, and mold pattern.
• Position and place the cope and drag halves together. Use paste as required by work instructions.
• When necessary, place paste onto pouring cups and secure them over the sprue in the mold.
• Shovel extra sand into wheelbarrow.
• Keep track of the number of molds completed and when order is complete switch pattern and gather necessary items (cores, different size flasks, etc.) for next work order.

SHELL CORE

• Shape sand cores used in molds, using air-set sand mixer and/or shell core blower.
• When necessary, mix sand for certain jobs based on work instructions.
• Remove cores from core boxes and place them into storage boxes or onto racks for transport to molding area
• Select the appropriate core box from work order and set-up the machine, making all necessary operation adjustments.
• Keep core boxes clean and report any excessive wear or damage to supervisor
• Report production quantities and times for each work order.
• Monitor each cycle and inspect the cores as they are made, making any adjustments that are necessary.
• Soot the core when necessary.
• Assist forklift driver in filling sand hopper.
• As necessary, add graphite to core box to aid in releasing the core.
• Wait the appropriate amount of time for the heat cycle to be complete.
• Flip and heat bottom of the core box, and then flip back to heat top of the core box using petroleum torch.
• When necessary, use files and other hand tools to smooth the surface, fix surface defects, and cut off excess parts of the core.
• Eject the core from core box and when necessary, use wedge to help release the core.
• Use air tools to free excess sand from the core box.
• Spray release onto core box between each core making cycle.
• Ice blast the core box as needed or at the end of the order run.
• When necessary, use a piece of glass to get built up graphite out of fins.
• When necessary, use a gauge to make an indent on a core.
• Use a bristled brush to clean core box.
• Use equipment as required by the work instructions.
• Scoop sand into the core box when necessary.
• Use board jig to make sure the core is the proper size and doesn’t hit the sides.

SO2

• Set up machines following work instructions for different jobs.
• Place drag, cope, and injection (blow) plate together and place into SO2 machine.
• Run machine according to work instructions.
• During curing time make sure supplies are stocked.
• When machine time is complete, pull core box out and remove the injection plate.
• Tap ejection plate and use compressed air to clean sand out of the holes in plate.
• Pull cope from the drag, the core piece will be attached to cope.
• Use ejection board to remove core from cope.
• Make sure core complies with casting needs and work instructions.
• If there is a bad core, place it into wheelbarrow and assess how the problem can be fixed for next casting.
• Use air tools to clean core box, place clay on areas if required, and spray release agent if core sticks to core box.
• If there is too much build up on core box use an emery cloth to clean the area.
• Place foam on casting cart and place inspected/finished core onto cart.
• Mark the finished core with shift color.

FREE FLOW

• Set up free flow machine with the correct core box per work instructions.
• Use work instructions to set up heat percentages for the cope and the drag.
• Operate free flow machine to dispense sand.
• Use air tools to clean out excess sand and graphite from core box.
• Spray parting agent into core box between run cycles.
• When necessary put graphite into core box.
• When necessary put grease mix onto the fins in the core box.
• Depending on core package size, use a hoist to lift core package out of free flow machine.
• Following work instructions, insert aluminum pins between fins of the core package.
• Use a file to push pins into core package so they are flush with the surface.
• Use files and other hand tools to clean surface defects.
• Every 24 hours or when there is a lot of buildup on core box, ice blast it.

QUALIFICATIONS AND REQUIREMENTS

At least one year of experience in a manufacturing setting is preferred.

Meet the requirements of the Molder Apprentice Program.

EDUCATIONAL REQUIREMENTS

Highschool diploma or its equivalent is preferred.

PHYSICAL REQUIREMENTS