Hands-on Melt Foreman (Electric Induction)

Job Description

Job Description

Job Summary

We are a small, tight-knit, and agile gray and ductile iron foundry in Erie, PA, looking for a Hands-on Melt Foreman to lead our melting and pouring operations. This is not a "desk job" or a purely administrative role. You will spend your day on the melt deck, leading a small crew by example, while remaining directly responsible for the safe and efficient operation of our electric coreless induction furnace .

The ideal candidate possesses a deep practical understanding of iron melting metallurgy, charge calculations, and furnace maintenance, combined with the grit and leadership required to run a safe, efficient shop floor.

Core Responsibilities

Shop Floor Leadership & Operations

• Lead by Example: Work directly on the melt deck alongside the crew, assisting with charging, slagging, pouring, and ladle prep as needed.
• Production Scheduling: Coordinate daily melt schedules to meet the demands of our green sand and no-bake molding lines.
• Crew Supervision: Train, mentor, and supervise melt deck operators, pourers, and lab technicians, ensuring strict adherence to operating procedures.

⚡ Technical Melting & Metallurgy

• Furnace Operation: Safely oversee and operate electric coreless induction furnace, monitoring power settings, temperatures, and melt rates.
• Charge Calculus & Chemistry: Calculate and execute precise material charge mixes (scrap, returns, alloys) to achieve targeted gray and ductile iron specifications.
• Quality Control: Perform and interpret spectrometer thermal analysis and chemical tests to adjust carbon, silicon, and alloy levels prior to tap-out.

Refractory & Equipment Maintenance

• Refractory Upkeep: Monitor furnace lining wear and manage the hands-on patching, ramming, and relining of furnaces and ladles.
• Equipment Care: Ensure routine preventive maintenance is completed on furnaces, water-cooling systems, electrical controls, and charging equipment.

Safety & Environment

• Enforce Safety Protocols: Maintain zero-tolerance compliance for PPE, moisture control on the deck (preventing water-in-melt explosions), and safe molten metal handling.
• Housekeeping: Maintain a clean, organized, and hazard-free melt department.

Requirements & Qualifications

• Experience: Minimum 3–5 years of hands-on experience on an iron melt deck, with at least 2 years in a supervisory, foreman, or lead operator capacity.
• Furnace Expertise: Direct, proven experience operating electric coreless induction furnaces is strictly required. (Cupola-only experience will not fit this environment).
• Technical Skills: Proficient in charge material calculations, carbon/silicon adjustments, and utilizing spectrometer equipment.
• Physical Capability: Ability to work in a hot, heavy industrial environment, stand for long periods, and lift up to 50 lbs.
• Mindset: A resourceful, self-starting leader who thrives in a small-business environment where everyone wears multiple hats.

Benefits & Perks

• Competitive wage based on direct foundry experience.
• Comprehensive healthcare, dental, and vision insurance.
• Paid Time Off (PTO) and paid holidays.

401(k): 3% company contribution, regardless of employee contribution.