Journeyman Molder / Molder - 3rd Shift

ECK INDUSTRIES INC•Manitowoc, WI

8d•Onsite

About The Position

Molders produce and assemble sand molds or related components used to manufacture aluminum castings. This role involves studying work instructions, operating heating equipment, positioning components, cutting spouts and holes, and maintaining a clean and safe working environment. Specific tasks vary depending on the molding process, including No-Bake, Green Sand, Shell Core, SO2, and Free Flow methods. Responsibilities include preparing patterns, filling and compacting sand, assembling molds, inspecting and repairing defects, and reporting production quantities. The position requires adherence to 6S standards and completion of daily inspections and housekeeping duties.

Requirements

At least one year of experience in a manufacturing setting is preferred.
Meet the requirements of the Molder Apprentice Program.

Responsibilities

Study work instructions to determine product specifications, tool requirements, and operational sequences.
Record quantities of materials and finished products, requisitioning additional supplies as necessary.
Operate and adjust 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.
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.
Place risers, down sprues, locater bars, filters, and chills into 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.
Ensure core box is placed directly under sand dispenser.
Use machine to start and stop sand flow coming from mixer.
Use a shovel to grab bad sand (dust) that comes out of the sand shoot first.
Use a 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).
Use compressed air to clean riser and sprue holes once core box is filled and packed with sand.
Remove riser caps from riser holes.
Ram up core.
Put a board on top of drag (the bottom when flipped on machine).
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.
Use a file or other hand tools to fix any surface defects.
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.
Ensure 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.
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.
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.
Ensure 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.
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.