Shell Finishing Processor - Deer Creek

United States of America
Oregon
Milwaukie
Airfoils
Deer Creek (DCA)
Operations
Full Time
March 1 2021

  


862

With more than 120 operations and about 20,000 employees worldwide, Precision Castparts Corp. is the market leader in manufacturing large, complex structural investment castings, airfoil castings, forged components, aerostructures and highly engineered, critical fasteners for aerospace applications. In addition, we are the leading producer of airfoil castings for the industrial gas turbine market. We also manufacture extruded seamless pipe, fittings, forgings, and clad products for power generation and oil & gas applications; commercial and military airframe aerostructures; and metal alloys and other materials for the casting and forging industries. With such critical applications, we insist on quality and dependability – not just in the materials and products we make, but in the people we recruit.

Headquartered in Portland, Oregon, this over 10 billion dollar company employs more than 20,000 people worldwide.  PCC has over 120 plants and has a presence in twenty-six states in the US and in over a dozen countries. PCC is relentless in its dedication to being a high-quality, low-cost and on-time producer; delivering the highest value to its customers and shareholders while continually pursuing strategic, profitable growth.

Effective early February 2016, Berkshire Hathaway, led by chairman and CEO Warren E. Buffett, acquired Precision Castparts Corp.

PCC Airfoils LLC has achieved its preeminent position in the manufacture of aircraft engine blades and vanes and is rapidly gaining market share in the Industrial Gas Turbines industry through pushing the boundaries of Advanced Technology. PCC Airfoils LLC is one of only a few companies in the world that possesses the technology and capability to cast blades and vanes with complex, internal cooling passages out of sophisticated superalloys for aerospace and Industrial Gas Turbine customers. PCC Airfoils LLC has the advantage of being the leader in the production of airfoils for aircraft engines and of capturing a growing share of the market for Industrial Gas Turbine castings. Several new state-of-the-art casting furnaces were recently installed in PCC Airfoils’ facilities along with new ceramic dip lines to handle the increased volume. The dip lines feature the most advanced technology available to ensure process repeatability, improving yields and facilitating on-time product delivery.
Based in Milwaukie, Oregon, Deer Creek facility principally manufactures Equiax Vane and Nozzle segments for the Industrial Gas Turbine (IGT) industry used in land-based turbine applications for power generation operations. Deer Creek has a wide range of manufacturing capabilities producing products ranging from 16 lbs to 250 lbs.

MISSION:

To deliver the highest quality shell to Casting on time by grinding, dewax, plugging, cleaning, inspecting, insulating and repairing ceramic molds.

 

PRINCIPAL ACCOUNTABILITIES:

1.  Shell Grinding

 

Objective:to prepare molds for dewax, deplasticize, flash fire and casting operations.

 

Essential Job Functions:

A.Grinds mold edges, vents, thermal-coupling tubes, pins and open cups to allow removal of wax per specifications.

B.Assures proper drying time between sealer dip and grinding.

C.Maintains lot integrity.

D.Takes shell weights as required.

E.Cleans handles and/or frames of excess shell materials.

F.Breaks down framed product by removing skirts, nuts, washers and shell material as needed.

G.Removes and cleans plastic band from mold platter (LPCS and LPCT only); pulls string for shell removal as needed. (SSBO only)

H.Loads dewax carts according to specifications.

 

2.  Dewax/Deplasticize

 

Objective: to remove wax from molds of water wash machine and/or high pressure steam autoclave.

 

Essential Job Functions:

A.Verifies load for size and weight requirements.

B.Secures loads for transport and pressurization of autoclave.

C.Loads autoclave, records time, operates autoclave.

D.Transfers loads to drying oven and operates oven. (SSBO only)

E.Removes part from autoclave; transports to shell inspection area.

F.Removes impurities from nuts, washers, bolts and frames. (LPCT only)

G.Cleans wax residue from underside of mold and seal openings.

H.Prepares hoppers for wax drainage from autoclave. (LPCT only)

I.Logs dewaxed mold weight onto computer terminal (Marginal job function at SSBO)

J.Cleans mold frames of excess ceramic material; transfers frames to storage area or cleaning department.

 

3.Flash Fire Furnace - SSBO only

 

Objective:to remove wax and plastic using flash fire furnace.

 

Essential Job Functions:

A.Starts and shuts down furnace, monitor operating controls.

B.Loads furnace, which operates at 1900 degrees Fahrenheit.

C.Maintains lot integrity.

D.Inspects load after furnace operation.

E.Completes logs and records.

 

4.  Inspection

 

Objective:to inspect and repair shells prior to shipment to casting.

 

Essential Job Functions:

A.Inspects shell for cracks and defects with a variety of hand inspection tools. LPCT only - Borescope used on limited basis if operator notices problem.

B.Makes repairs with cement, wax, slurry first dip solution or mesh as needed.

C.Plugs vents, holes, risers, and pours cups.

D.Installs filters. (SSBO only)

E.Verify lot integrity, checks ID markings.

F.Verifies water weight to analyze metal needs, checks for leaks.

 

5.  Insulation - Final Preparation

 

Objective:to attach insulating material to shell as required.

 

Essential Job Functions:

A.Cuts, wires or uses mud to attach insulating material to shell as required.

B.Inspect shells for defects, including storage damage.

C.Marks part and lot number on shell.

D.Verifies lot integrity.

E.Rolls insulated parts over to upright position for final processing.

F.Places thermal-couples into mold as directed. (LPCS only)

G.Places part on special framing fixtures (LPCS only); transports to casting.

H.Assists engineers with template design and modifications of insulating material. (Marginal job function at SSBO)

 

6.  Maintains and completes all logs and records; assures shell ID matches paperwork during each process step and transportation.

 

7.  Housekeeping

A. Cleans work area which may include grinding room sump.

 

8.  Meets all production and quality standards.

 

9.  Safety

 

Objective:to take responsibility for and demonstrate safe work practices.

 

NOTE: for job positions that require respiratory protection (more than a filtering face piece – dust mask):

In compliance with the Oregon Occupational Safety and Health Division Personal Protective Equipment standard for Respiratory Protection, OAR 437, Div. 2/I 1910.134 and Oregon Health Division Rules for the Control of Radiation, OAR 333. Div. 120 (333-120-300 through 330), certain tasks within this job position require/may require the use of a NIOSH-approved respirator. An individual will not be assigned to these tasks if the person is not able to work under these conditions. Respirator selection will be based on the work performed, exposure information, duration of use and any other relevant factors. If a tight-fitting respirator is required, facial hair, temple pieces on glasses or other items that interferes with the face-to-face piece seal of the respirator are not permitted.

 

Essential Job Functions:

 

A.   Adheres to plant and department safety rules

B.   Safely operates all equipment and tools.

C.   Identify and report safety problems.

D.   May be required to work with hazardous waste.

 

OTHER (MARGINAL) ACCOUNTABILITIES:

10. Performs other tasks as directed.

 

ESSENTIAL EQUIPMENT, VEHICLES, TOOLS AND/OR MACHINERY USED:

1.  forklift

2.  manual push cart and autoclave cart

3.  hand grinders

4.  shovels, floor scrapers, brooms squeegees

5.  basic hand tools (e.g. hammers, wrenches, knives, prybars, pliers, etc.)

6.  borescope (LPCT only)

7.  scale

8.  wheel dresser (grinding/sharpening wheel)

9.  roll-over equipment

10. autoclave

11. hoist

12. slings straps

13. computer

14. clamps (LPCT and SSBO only)

15. wire cutters

16. shell boxes barrels (LPCT only)

17. bold washer (LPCT only)

18. grates (LPCT and SSBO only)

19. cheese rafasil cloth

20. prop stands

21. tape

22. flashlight dental mirrors

23. Pedestal grinder (LPCT only)

TRAINING:

1.  Training is provided on the job.

2.  PCC's Forklift Driving Safety Certification Training must be completed.

3.  Radiation Safety Training must be completed. (LPCT only)

4.  May be required to complete hazardous waste management training.

QUALIFICATIONS:

1.  Experience in the investing area preferred,

                        OR

An equivalent combination of classroom training and work experience.

2.  Ability to perform basic mathematical calculations. (addition, subtraction)

3.  Ability to read, follow and interpret specification on Technique Cards, routers, and other special instructions.

4.  Ability to communicate effectively both verbally and in writing.

5.  Physical ability to perform the essential job functions.





All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.