Hands-on Melt Foreman (Electric Induction)

Job Summary: We are a small, tight-knit, and agile gray and ductile iron foundry in Erie, PA, looking for aHands-on Melt Foremanto 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 ourelectric 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.

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 operatingelectric coreless induction furnacesis 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.