Casting Operator - Oxygen Free Copper & Alloy Plant - Copper

Purpose/Objective

A Casting Operator works in the plant's cast house, directly operating and monitoring equipment to produce high-quality oxygen-free copper rod (OFC) products and copper alloy rods (Cu-Ag, Cu-Mg). The role is physically demanding and requires a strong mechanical aptitude, attention to detail, and a strict adherence to safety protocols. Operators are responsible for controlling the flow of molten metal, inspecting finished castings, and ensuring all quality and production standards are met.

Key Responsibilities of Role

- Machine Operation: Operate and monitor casting machines, furnaces, and other related equipment to produce OFC and copper alloy products according to specifications. - Melting and Pouring: Regulate the flow of molten copper and alloys from the furnace into the casting molds or continuous casting line. - Quality Control: Conduct visual and dimensional inspections of castings to check for defects like cracks and bubbles, and ensure the product meets all quality standards. - Process Monitoring: Read and record data from gauges, pyrometers, and other instruments to monitor the casting process and adjust machine settings as needed to control temperature and cooling. - Raw Material Handling: Weigh and load raw materials, including copper cathodes and other alloying elements, into the furnace. Skim or remove dross and other impurities from the molten metal. - Equipment Maintenance: Perform routine and preventive maintenance on casting equipment. This includes cleaning molds and machinery and conducting minor repairs to address issues. - Safety Compliance: Adhere to all plant safety rules and procedures. This involves wearing and maintaining appropriate personal protective equipment (PPE), ensuring a clean and organized work area, and reporting any hazards or equipment malfunctions. - Team Collaboration: Work effectively with other team members, supervisors, and maintenance personnel to ensure a smooth and efficient production process. - Record Keeping: Accurately complete production reports and document details such as output, defects, and machine settings.

Technical Competencies

Alloy Knowledge and Process Control,Equipment Operation and Maintenance,Quality Assurance and Defect Prevention,Safety and Environmental Compliance

Qualifications and Experience

Education: High school diploma or equivalent is required. A vocational qualification or certification in a related field, such as metallurgy, industrial manufacturing, or foundry technology, is preferred. Experience: Previous experience as a casting operator or in a similar role within a metal processing plant (ferrous or non-ferrous), foundry, or continuous casting operation is highly desired. Physical Requirements: Ability to stand for extended periods, lift heavy loads, and work in a loud, hot, and fast-paced industrial environment. Minimum 2–3 years of experience in metal casting or furnace operations, preferably in copper or alloy plants.