Shell Operator - 2nd Shift

Schedule: Monday - Friday: 2:30 PM – 11:00 PM

Incentives: 5% Shift Differential + Quarterly Incentive Bonus + Overtime Opportunities

Purpose Responsible for preparing molds, applying slurry coatings, and operating robotic and manual dipping equipment to ensure proper coating of wax pattern assemblies in accordance with established process specifications, quality standards, and safety requirements in a continuous production environment.

Essential Job Functions

• Read and interpret shell process sheets and work instructions for each production part number.
• Prepare molds and pattern assemblies for processing by removing from racks and installing handling fixtures or handles as required.
• Operate robotic dipping equipment, including monitoring, adjusting speed and cycle times, and responding to alarms by removing molds and resetting equipment as necessary.
• Continuously monitor dip cycles to ensure proper coating coverage and process consistency.
• Manually immerse wax assemblies and molds into designated washing solutions and slurry tanks in accordance with process specifications.
• Apply initial and subsequent slurry coatings, ensuring complete and uniform coverage of all surfaces.
• Operate manipulators and handling equipment to position, rotate, and coat molds effectively.
• Perform specialized handling procedures for specific part numbers, including identifying wet spots, clearing pockets, removing loose sand, and ensuring proper slurry adhesion.
• Prepare and replenish slurry mixtures by accurately combining solids and liquids according to established formulas and procedures.
• Clean and maintain slurry tanks, fluidized beds, and associated equipment, including performing periodic turnaround operations.
• Maintain accurate process documentation, including recording dipping times, dates, and other required data on process sheets.
• Perform continuous visual inspection of molds and coatings to identify defects or inconsistencies.
• Maintain work areas in a clean and orderly condition through sweeping, washing, scraping, and proper disposal of waste materials.
• Operate forklifts to transport materials, deliver supplies, and remove waste products safely.
• Follow all safety rules, procedures, and PPE requirements at all times.
• Report equipment malfunctions, process deviations, or safety concerns to supervision promptly.
• Perform additional duties of varying complexity as assigned.

Special Skills And Physical Requirements

• Standing/Walking:

• Continuous standing and walking for extended periods (8–12 hours per shift) on hard industrial surfaces such as concrete.

• Lifting/Carrying:

• Frequently lifts, carries, pushes, and pulls molds, assemblies, and materials weighing up to 35 lbs, with occasional lifting up to 35 lbs without assistance.

• Manual Handling & Grip Strength:

• Repetitive and forceful use of hands and arms to grasp, grip, lift, and maneuver molds and equipment, often in wet, slippery, or coated conditions.

• Repetitive Motion:

• Continuous, repetitive upper body movement including immersion of molds, operation of manipulators, cleaning tasks, and equipment interaction throughout the shift.

• Bending/Stooping/Kneeling/Twisting:

• Frequent bending, stooping, kneeling, and twisting to access tanks, racks, lower equipment, and work surfaces.

• Reaching:

• Regular reaching at, below, and above shoulder height to load/unload racks, immerse molds, and operate robotic or manual equipment.

• Visual Requirements:

• Constant visual attention to detail, including close vision, distance vision, depth perception, and the ability to identify coating defects, inconsistencies, and process issues.

• Work Pace & Coordination:

• Ability to maintain focus and coordination in a continuous production environment, including monitoring automated equipment while performing manual tasks.

PERFORMANCE EXPECTATIONS

• Maintain productivity levels in line with department targets and daily commit goals.
• Complete assigned work within required process timing windows (e.g., prime and backup dry times).
• Produce consistent, defect-free coatings with minimal rework or scrap.
• Maintain work pace to support continuous flow and avoid bottlenecks to Debase and Dewax.
• Demonstrate reliability, consistency, and accountability in a high-paced production environment.

Reporting Relationships

• Reports directly to the Shell Supervisor

Education And Experience

• 1 year of manufacturing experience preferred; foundry or metals-processing experience is a plus.
• Demonstrated ability to comprehend and apply ordinary arithmetic, decimals, and fractions in daily work tasks.