Key Responsibilities and Required Skills for a Forge Worker / Forge Press Operator

🎯 Role Definition

As a Forge Worker, you are the artisan at the heart of our industrial process, transforming raw metal into mission-critical components. You will be responsible for the entire forging cycle, from heating materials to precise temperatures to operating heavy presses and hammers that shape parts to exacting standards. This role requires a unique blend of physical strength, technical skill, and an unwavering commitment to safety and quality. You will work hands-on with powerful machinery, read complex blueprints, and ensure every piece you create meets rigorous industry specifications. This is a pivotal position for an individual who takes pride in tangible, high-quality work and thrives in a fast-paced, heavy manufacturing environment.

📈 Career Progression

Typical Career Path

Entry Point From:

General Laborer (in a metalworking or manufacturing environment)
Machine Operator Assistant
Trade School Graduate (Welding/Metalworking)

Advancement To:

Forge Shop Lead / Cell Leader
Quality Control Inspector (Metals)
Forge Shop Supervisor or Foreman

Lateral Moves:

CNC Machinist
Heat Treat Technician
Welder / Fabricator

Core Responsibilities

Primary Functions

Operate open and closed die forging presses, hammers, and upsetters to perform a variety of forming, shaping, and cutting operations on heated metals.
Set up, adjust, and maintain forging dies, rams, and other tooling in accordance with job specifications and production schedules.
Interpret complex engineering blueprints, work orders, and technical drawings to determine forging requirements, including dimensions, tolerances, and material specifications.
Master the control and monitoring of induction heaters and furnaces to bring various metal alloys (steel, titanium, aluminum) to the precise forging temperature required for optimal malleability.
Manipulate and maneuver heavy, hot metal workpieces using tongs, hoists, and overhead cranes, ensuring safe and efficient transfer between furnace and press.
Perform in-process quality inspections using precision measuring instruments such as calipers, micrometers, and go/no-go gauges to verify conformance to specifications.
Identify and troubleshoot common forging defects, such as laps, cracks, or non-fills, making necessary adjustments to the process, temperature, or equipment.
Execute hot trimming and piercing operations to remove flash and form features on forged parts as a part of the integrated production process.
Monitor machine operations, including pressure, cycle times, and temperatures, adjusting controls to maintain operational efficiency and part quality.
Perform visual inspections of finished forgings to ensure they are free from surface defects and meet all cosmetic and structural standards.
Maintain a deep understanding of metal properties and their behavior under heat and pressure to anticipate and prevent forging issues.
Adhere strictly to all company and industry safety protocols, including the proper use of personal protective equipment (PPE) like heat-resistant suits, face shields, and gloves.
Accurately document production and quality control data, including part counts, scrap rates, and any deviations from the standard process.
Conduct routine operator-level preventative maintenance on forging equipment, including lubrication, cleaning, and minor adjustments to ensure machine reliability.
Coordinate with material handlers and furnace operators to ensure a continuous and efficient flow of properly heated material to the forging press.

Secondary Functions

Support production analysis by providing accurate logs and data on cycle times, material usage, and equipment downtime.
Contribute to continuous improvement initiatives by suggesting process enhancements, tooling modifications, or workflow changes based on hands-on experience.
Collaborate with the maintenance department to diagnose complex equipment malfunctions and assist in repair and overhaul activities.
Participate in daily production meetings, safety briefings, and team huddles to align on operational goals, safety concerns, and production priorities.

Required Skills & Competencies

Hard Skills (Technical)

Forge Press/Hammer Operation: Proven ability to operate hydraulic presses, mechanical presses, or forging hammers.
Blueprint Reading: Expertise in reading and interpreting detailed industrial blueprints and technical schematics.
Die Setup & Alignment: Skill in installing, aligning, and securing forging dies and tooling.
Precision Measurement: Proficiency with calipers, micrometers, and other metrology tools for quality inspection.
Heat Treatment Principles: Strong knowledge of heating various metals to specific temperatures for forging.
Overhead Crane & Hoist Operation: Certified or experienced in safely operating cranes for material handling.
Basic Machine Maintenance: Ability to perform routine preventative maintenance and minor troubleshooting on heavy machinery.
Metal Properties Knowledge: Understanding of how different steel alloys and metals react to heat and pressure.

Soft Skills

Safety Consciousness: An absolute commitment to following safety procedures in a high-hazard environment.
Attention to Detail: Meticulous focus on part quality, measurements, and process parameters.
Physical Stamina & Strength: Ability to handle the physical demands of the job, including working in a hot environment and manipulating heavy materials.
Problem-Solving: The capacity to identify issues with equipment or parts and implement effective solutions quickly.
Teamwork and Communication: Ability to work and communicate effectively with supervisors, quality inspectors, and other team members.
Strong Work Ethic: Dependable, punctual, and motivated to meet production targets without compromising quality.

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 a relevant field.

Relevant Fields of Study:

Metalworking or Metallurgy
Industrial Technology or Manufacturing
Welding Technology

Experience Requirements

Typical Experience Range:

2-5 years of hands-on experience in a heavy industrial, metalworking, or manufacturing environment.

Preferred:

3+ years of direct experience operating large-scale forging presses, with demonstrated skill in die setup, troubleshooting, and working with a variety of alloys. Experience in an aerospace or automotive forging environment is a significant plus.