Key Responsibilities and Required Skills for Forge Operator

🎯 Role Definition

As a Forge Operator, you are the skilled artisan at the heart of our industrial manufacturing process. You will command powerful machinery—including hydraulic presses, mechanical presses, and forging hammers—to transform raw metal billets into high-strength, precision-engineered components. This role requires a unique blend of physical strength, technical aptitude, and an unwavering commitment to safety and quality. You will be responsible for the entire forging process, from heating materials to precise temperatures and executing complex die setups to performing in-process quality inspections. Success in this position means playing a vital part in creating the fundamental parts that build our world, from aerospace components to automotive drivetrains.

📈 Career Progression

Typical Career Path

Entry Point From:

Machine Operator Helper or Assistant
General Manufacturing Laborer
Industrial Maintenance Apprentice

Advancement To:

Lead Forge Operator or Cell Leader
Forge Setup Technician
Forge Supervisor or Production Foreman

Lateral Moves:

Quality Control Inspector
CNC Machinist
Heat Treat Technician

Core Responsibilities

Primary Functions

Operate heavy forging equipment, such as hydraulic/mechanical presses, upsetters, and drop hammers, to shape metal parts according to engineering specifications.
Set up, install, and align dies, tooling, and fixtures in forging presses, ensuring all components are secure and correctly calibrated for production runs.
Monitor and control induction heaters or furnaces to bring metal stock (steel, aluminum, titanium, etc.) to the precise plastic-forming temperature required for forging.
Skillfully transfer heated billets from the furnace to the press using tongs, manipulators, or automated equipment, maintaining temperature and safety.
Accurately position and manipulate workpieces within the dies through single or multi-stage forging processes to achieve the desired shape and dimensions.
Interpret complex blueprints, work orders, and setup sheets to determine operational sequences, machine settings, and required tooling.
Conduct first-piece and in-process quality inspections using precision measuring instruments like calipers, micrometers, and specialized gauges to ensure parts meet strict tolerance standards.
Visually inspect finished and in-process forgings for defects such as cracks, laps, scale, or non-fills, and take corrective action to resolve issues.
Make necessary adjustments to machine controls, die alignment, or temperatures to maintain part conformity and process efficiency throughout a production run.
Consistently meet or exceed established production quotas and efficiency targets while upholding the highest standards of quality and safety.
Perform routine operator-level preventative maintenance, including lubricating machinery, checking fluid levels, and cleaning equipment to ensure optimal performance.
Adhere rigorously to all company and industry safety protocols, including Lockout/Tagout (LOTO) procedures, proper use of Personal Protective Equipment (PPE), and safe material handling.
Operate overhead cranes, jib cranes, and forklifts to safely transport raw materials, dies, and finished products throughout the facility.
Maintain accurate and detailed production logs, quality control records, and maintenance reports, either manually or using a computer-based system.
Troubleshoot common equipment malfunctions and process deviations, communicating complex issues to maintenance or engineering teams for resolution.
Monitor die condition during production, identifying signs of wear, damage, or misalignment and initiating die changes or repairs as needed.
Maintain a clean, organized, and safe work environment by following 5S principles and participating in general housekeeping tasks.
Collaborate effectively with supervisors, quality assurance personnel, and fellow operators to optimize workflow and resolve production challenges.
Handle and manage scrap material, ensuring it is properly segregated and disposed of according to company procedures.
Actively participate in continuous improvement programs, suggesting process enhancements to improve safety, quality, and productivity.

Secondary Functions

Assist in the cross-training and mentoring of new or less-experienced operators on equipment operation and safety standards.
Contribute to root cause analysis activities for non-conforming products or process failures.
Support the maintenance team during more extensive machine repairs or preventative maintenance shutdowns.
Participate in team safety meetings and contribute to the development of safer work practices.

Required Skills & Competencies

Hard Skills (Technical)

Press & Hammer Operation: Proficiency in operating large-scale mechanical presses, hydraulic presses, and/or forging hammers.
Blueprint Reading: Ability to read and accurately interpret technical drawings, schematics, and geometric dimensioning and tolerancing (GD&T).
Precision Measurement: Skilled in using calipers, micrometers, height gauges, and other metrology tools to verify part dimensions.
Die Setup & Alignment: Experience with the installation, securing, and calibration of heavy forging dies and related tooling.
Furnace/Induction Heating: Knowledge of operating industrial furnaces or induction heaters to achieve specific material temperatures.
Overhead Crane/Forklift Operation: Certified or experienced in operating material handling equipment to move heavy loads.
Basic Metallurgy: Foundational understanding of how heat and pressure affect the properties of various metals.
Machine Maintenance: Ability to perform basic preventative maintenance tasks like lubrication, cleaning, and minor adjustments.
Troubleshooting: Aptitude for diagnosing and resolving common issues with equipment and the forging process.
Shop Math: Competency in performing basic mathematical calculations, including fractions and decimals, relevant to manufacturing.

Soft Skills

Safety Consciousness: An unwavering commitment to following safety rules and maintaining a safe work environment.
Attention to Detail: Meticulous in monitoring processes and inspecting parts to ensure the highest quality output.
Physical Stamina & Strength: Ability to stand for long periods, lift heavy objects, and work in a hot, physically demanding environment.
Problem-Solving: The ability to think critically and react effectively when unexpected issues arise during production.
Teamwork & Communication: Strong interpersonal skills to collaborate with team members and clearly communicate information.
Dependability & Work Ethic: A reliable and punctual team player with a strong internal drive to succeed.
Resilience: The capacity to work effectively under pressure and adapt to changing production priorities.
Mechanical Aptitude: An intuitive understanding of how machines and mechanical systems work.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED equivalent.

Preferred Education:

Certificate or Associate's Degree from a vocational or technical college in Manufacturing Technology, Industrial Mechanics, or a related skilled trade.

Relevant Fields of Study:

Metallurgy
Machine Tool Technology

Experience Requirements

Typical Experience Range:

2-5+ years of hands-on experience in a heavy industrial setting, preferably with direct experience in open-die, closed-die, or ring rolling forging operations.

Preferred:

Prior experience setting up and operating forging presses over 1,000 tons.
Demonstrable experience working with specific alloys such as steel, titanium, or aluminum.
Forklift and/or overhead crane certification is highly desirable.