Shell Removal Operator LPCT 841

Mission

This position requires Operators to be willing and able to rotate through all of the shell removal/cleaning processes as dictated by product flow and customer throughput requirements. Since the timing and duration of the processes for shell removal/cleaning varies from day-to-day and shift-to-shift, rotation through all of the processes results in efficiencies in product flow, cost of operation and improves our ability to meet customer throughput requirements.

The position exists to remove shell material, core material, and scale from castings and their gating systems by means of a variety of related processes.

Primary Job Functions

• 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; and
• 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; and
• 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; and
• 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; and
• 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; and
• 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;
• Wears protective gear when working with chemicals;
• Clean tanks and remove sludge; and
• Neutralize any hazardous materials.
  

Notes

• Variations in process and equipment exist between plants. Some of the above accountabilities may not pertain to all plants, nor is the list all inclusive of all activities at each plant.
• Pay progression in this job is governed by the requirements in the step progression record.
  
  

Other Accountabilities

• 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; and
• 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; and
• Check, charge and change batteries on forklift.
• Additional Requirements:
  
  

• Meet all production and quality standards;
• Complete logs and records; and
• 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
• Wear PAPR, respirator, purified air helmet, protective coveralls, safety glasses, safety goggles, double hearing protection, and safety shoes with metatarsal protection.
  
  

Training

• Basic Skills training.
• Training is provided on the job.
• PCC's Forklift Driving Safety Certification Training must be completed.
• May be required to complete hazardous waste management training.
• 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 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.