Ladle Metallurgy Furnace Crew Member

The newly created Company, FerroWorks, has locations in Pittsburgh, McKees Rocks, and Kutztown, PA including McConway and Torley and Standard Forged, which have been in continuous operations since 1869, the same year the first US transcontinental railroad was completed. We have been able to meet the needs of our customers with a steady, dependable and economical supply of high-quality railroad industry products. As McConway is the original designers of the first standard automatic coupler, continued innovation and craftsmanship have and has led to a product line that includes every ARR approved coupler as well as custom coupler solutions, which are all proudly cast in the US.

Kutztown Foundry and Machine (KFM) is looking for a Ladle Metallurgy Furnace (LMF) Crew. This crew is made up of four (4) positions performing as one unit. The LMF Crew includes LMF Ladle Operator Lead and three (3) LMF Melt Helpers (Craneman x1, Melt Helpers x2).

As the LMF Ladle Operator Lead, you are responsible for controlling and overseeing the operation of the LMF, ensuring that the steel refining process is carried out efficiently, safely, and in accordance with established standards. This position requires knowledge of metallurgy, furnace operation, and the ability to manage the chemistry and temperature of molten steel to meet production specifications.

As the LMF Melt Helper, you are responsible for assisting the LMF Ladle Operator to meet ladle availability. In this position you will also be responsible for safely and efficiently operating cranes that handle molten metal and other heavy materials within the steel foundry. This role is critical in ensuring the continuous operation of the foundry by supporting the movement of molten steel, scrap, and raw materials while adhering to strict safety protocols. In this position you will also deliver metal to specifications safely, accurately and on time. Keep furnaces full, and safely and thoroughly clean the furnaces and ladles.

Location: Kutztown, PA

Shift: Must be able to work any shift

Key Responsibilities:

• Operating and monitoring the ladle metallurgy furnace (LMF) to refine molten steel to the desired chemical composition and temperature
• Adding alloying elements, fluxes, and other materials to the molten steel as per the specifications required for the final product
• Monitoring and controlling the temperature, pressure, and atmosphere inside the furnace using digital or manual controls
• Conducting sampling and testing of molten steel to ensure it meets quality standards and specifications for carbon content, temperature, and chemical composition
• Adjusting the furnace settings to maintain the correct steel properties during the refining process
• Operating and maintain equipment such as ladles, injectors, and slag handling tools
• Partnering with metallurgists and other operators to ensure smooth operation and coordinate steel production schedules
• Performing routine checks and maintenance on LMF equipment, reporting any issues or defects to maintenance personnel
• Ensuring the proper handling and disposal of slag, byproducts, and other waste materials from the refining process
• Maintaining accurate records of operational activities, including temperature, chemistry, and material inputs for traceability and quality control
• Following all safety protocols, including the proper use of personal protective equipment (PPE), and ensure safe operation in high-temperature and hazardous environments
• Participating in the troubleshooting and repair of any issues related to the LMF or other equipment as needed

• Operating overhead cranes, magnetic cranes, and other equipment to move molten metal, raw steel, and other materials between workstations, ladles, furnaces, and casting machines
• • Monitoring the temperature and condition of molten metal to ensure safety standards are met
  • Inspecting crane equipment regularly to ensure safe operation and report any malfunctions or maintenance needs
  • Assisting in the loading and unloading of materials from trucks and storage areas
  • Partnering with other foundry workers, including metal pourers and operators, to ensure smooth operations during the casting process
  • Maintaining detailed logs of crane usage, safety checks, and any incidents or accidents
  • Following all safety protocols, including wearing proper PPE (Personal Protective Equipment), and ensuring that safety measures are adhered to in a hazardous environment
  • Performing routine maintenance or assist maintenance personnel in keeping crane equipment in optimal working condition
  • Ensuring that all molten metal transfers are performed with precision and in a timely manner to maintain production schedules

Required Skills and Qualifications:

• High school diploma or equivalent; technical certifications or training in metallurgy or industrial operations are preferred
• Previous experience operating a ladle metallurgy furnace or similar steel refining equipment is highly desirable
• Knowledge of steelmaking processes, including refining, alloying, and temperature control
• Familiarity with controlling furnace parameters, such as oxygen flow, temperature, and alloying material additions
• Ability to interpret chemical analysis and adjust the refining process accordingly
• Strong understanding of safety regulations and ability to work in high-risk environments
• Good communication skills and the ability to work as part of a team
• Ability to follow strict operational procedures and quality standards

Physical Demands:

• Must be able to stand, walk, and work in a hot and noisy environment for extended periods
• Ability to handle and manipulate heavy materials, such as ladles, molten metal, and slag, using overhead cranes or other lifting equipment
• Ability to wear and work with personal protective equipment (PPE), including heat-resistant gloves, face shields, and hearing protection
• Capability to handle high-pressure situations and work under tight production timelines

• Must be able to lift heavy objects (up to 75 pounds) and operate cranes and lifting equipment
• • Ability to work in high-temperature environments, with exposure to molten metal and other hazardous conditions
  • Stamina to work long hours, often in shifts, and stand or walk for extended periods

Working Conditions:

• Work environment includes plant, warehouse, production and non-production areas and plant grounds
• This position may require work/maintenance coverage beyond the normal hours, shift, and on weekends/holidays
• Ability to tolerate both high and low temperatures, loud noises typical of a manufacturing plant

Safety Activities:

• Be aware of and observe all safety practices. Including but not limited to- Safety glasses, safety boots, hearing protection, etc… as required
• Know and follow all safety rules and procedures
• Participate in safety committees and initiatives as assigned

Safety Sensitive: Yes

Benefits:

• Health & Pharmacy
• Dental & Vision
• Critical Illness
• Flexible Spending Accounts
• Company Paid Life & AD&D Insurance
• Voluntary Life & AD&D Insurance
• 401(k) W/Company Match
• Short-Term Disability
• Voluntary Long-Term Disability
• Employee Assistance Program