Casting Production Operator

Job Summary:

Bharat Forge is seeking a highly skilled and experienced Casting Production Operator to oversee and manage various processes in our metal production and casting operations. The ideal candidate will possess a broad range of technical skills, including furnace operation, casting, machining, testing, material handling, and basic maintenance. This role requires both physical and mental capability to ensure that production processes are carried out safely, efficiently, and to the highest standards.

Key Responsibilities:

• Furnace Operations:
• Set up, adjust, operate, and maintain remelting furnaces, skimming machines, and charging equipment.
• Prepare aggregates, auxiliary materials, and manage energy supply systems (air volume, temperature, fan blast, gas burner, etc.).
• Load raw materials and alloys into the furnace using forklifts and other material handling equipment.
• Monitor and adjust melt composition through sampling and analysis to ensure alloy quality.
• Skim dross from furnace and prepare equipment for casting operations.

• Casting Operations:
• Produce molds and cores using various molding processes and prepare molds for casting.
• Set up, operate, and monitor pressure and gravity die-casting equipment.
• Inspect and repair mold and pattern equipment to eliminate defects.
• Rework castings through blasting, grinding, deburring, and fettling to meet quality standards.
• Assist with the maintenance of casting equipment and troubleshoot production issues.

• Machining & Equipment Operation:
• Operate CNC lathes, perform setup and adjustment, and program production equipment for efficient operation.
• Read and interpret technical drawings and perform quality checks using measuring equipment.
• Optimize ongoing production and document production processes for continuous improvement.

• Non-Destructive Testing (NDT):
• Perform non-destructive testing (NDT) to evaluate material integrity and ensure compliance with industry standards.
• Calibrate and operate testing equipment, analyze findings, and document results for quality assurance.

• Material Handling & Crane/Forklift Operations:
• Safely operate overhead cranes and forklifts to move materials
• Perform routine inspections and maintenance of lifting equipment to ensure safety and functionality.
• Load and unload materials from vehicles and ensure proper storage in the facility.

• Basic Maintenance Skills:
• Perform routine maintenance on production equipment, including cleaning, lubricating, and inspecting machinery to prevent breakdowns.
• Carry out minor repairs and adjustments to machinery, ensuring continuous and efficient operation.
• Collaborate with the maintenance team to address complex equipment issues when necessary.
• Ensure that all maintenance activities are recorded and comply with company standards and safety protocols.

• Production Monitoring & Troubleshooting:
• Use electronic data processing systems to monitor and control production parameters from operator desks (HMI) and control platforms.
• Detect, analyze, and troubleshoot faults in production processes to minimize downtime.
• Document production results and maintain accurate records of operational data.

Qualifications:

• Experience:
• Minimum of 4 years of experience in a heavy industrial setting, a plus would be experience in furnace operation, casting, machining, material handling, and equipment maintenance.

• Technical Skills:
• Proficiency in operating and maintaining CNC machinery, furnaces, and casting equipment.
• Ability to obtain ASNT Level II certification in non-destructive testing (NDT) or equivalent.
• Experience with forklifts, overhead cranes, and other material handling equipment.

• Maintenance Skills:
• Basic knowledge of routine machinery maintenance and troubleshooting techniques.
• Ability to troubleshoot and carry out minor repairs and adjustments to production equipment.
• Strong knowledge of mechanical, electrical, pneumatic, and hydraulic systems.
• Proficiency in using diagnostic tools, hand tools, and specialized equipment.
• Ability to understand and convert metric and standard measurements.

• Education:
• High school diploma or equivalent required. Technical training in mechanical engineering, CNC technology, or related field preferred.

General Requirements:

• Strong technical and analytical skills with the ability to read and interpret technical drawings.
• Attention to detail and commitment to high-quality production standards.
• Handles the physical demands of the job, including standing, bending, pulling, pushing, and lifting at least 50 pounds.
• Familiarity with OSHA regulations and industry safety standards.
• Strong communication skills and the ability to work independently or as part of a team.