Key Responsibilities and Required Skills for Forging Technician

🎯 Role Definition

A Forging Technician, also known as a Forge Operator, is a skilled trades professional at the heart of the heavy manufacturing process. This role is responsible for operating powerful machinery, such as presses and hammers, to shape metal into high-strength, durable components. By heating metal to precise temperatures and applying immense force, Forging Technicians create parts that are critical to the safety and performance of products in the aerospace, automotive, energy, and defense industries. This physically demanding yet rewarding position requires a strong mechanical aptitude, an unwavering commitment to safety, and the ability to produce parts that meet exacting quality standards and engineering specifications.

📈 Career Progression

Typical Career Path

Entry Point From:

Manufacturing Apprentice
General Production Laborer
Machine Operator Assistant

Advancement To:

Lead Forging Technician / Cell Leader
Forge Shop Supervisor or Foreman
Quality Control Inspector / Technician
Process Engineer

Lateral Moves:

CNC Machinist
Heat Treat Technician
Welder / Fabricator

Core Responsibilities

Primary Functions

Set up, operate, and maintain a variety of forging equipment, including hydraulic and mechanical presses, hammers, and upsetters, according to specific work orders and blueprints.
Read and interpret complex blueprints, work orders, and production schedules to determine specifications, such as material type, tooling requirements, and sequence of operations.
Perform critical in-process quality inspections of forged parts using various precision measuring instruments, including calipers, micrometers, and specialized gauges, to ensure conformance to strict quality standards.
Monitor and control furnace and induction heater temperatures and heating cycles to ensure metal reaches the optimal forging temperature without compromising material properties.
Execute complex die changes, tooling setups, and adjustments on forging equipment, ensuring proper alignment, securement, and functionality for each production run.
Safely and proficiently operate overhead cranes, jib cranes, and forklifts to transport heavy dies, raw materials, and finished parts throughout the manufacturing facility.
Perform routine preventative maintenance on all forging equipment, including lubrication, inspection of hydraulic/pneumatic systems, and documentation of maintenance activities.
Troubleshoot and diagnose operational or equipment malfunctions in real-time, making necessary adjustments or escalating complex issues to the maintenance department to minimize downtime.
Strictly adhere to all company and industry safety policies and procedures, including Lock-Out/Tag-Out (LOTO), personal protective equipment (PPE) requirements, and safe material handling practices.
Maintain accurate and detailed production records, including part counts, cycle times, downtime, and quality inspection results, using manual logs or computer-based data entry systems.
Visually inspect raw billets and stock material for defects, scale, or inconsistencies prior to the heating and forging process to prevent substandard outputs.
Adjust machine parameters, such as pressure, stroke, and speed, during operation to maintain part consistency and dimensional accuracy throughout the production run.

Secondary Functions

Collaborate with the Quality Assurance team to identify the root cause of defects and implement effective corrective actions to prevent recurrence.
Assist engineers and supervisors with process improvement projects, new product introductions, and trial runs to enhance operational efficiency and product quality.
Maintain a clean, organized, and safe work area by actively applying 5S principles (Sort, Set in Order, Shine, Standardize, Sustain).
Handle and manage forging dies, including pre-heating, application of lubricants, and proper storage procedures to maximize their operational lifespan and performance.
Operate auxiliary equipment such as trim presses, shot blast machines, or grinders to complete the post-forging finishing process of parts.
Participate actively in continuous improvement and lean manufacturing initiatives aimed at reducing waste, improving safety, and increasing overall productivity.
Provide training, guidance, and mentorship to apprentice technicians or new team members on standard operating procedures and critical safety protocols.
Communicate effectively with team members, supervisors, and support departments (Maintenance, Quality) to ensure a smooth and coordinated workflow across shifts.

Required Skills & Competencies

Hard Skills (Technical)

Operation of Hydraulic & Mechanical Forging Presses/Hammers
Blueprint and Technical Drawing Interpretation
Precision Measurement & Inspection (Calipers, Micrometers, Gauges)
Die Setting and Heavy Tooling Changes
Overhead Crane and Forklift Operation (Certification preferred)
Basic Metallurgy and Heat Treating Principles
Industrial Machine Maintenance and Troubleshooting
Furnace and Induction Heater Operation & Control
Knowledge of Lock-Out/Tag-Out (LOTO) procedures

Soft Skills

Exceptional Attention to Detail
Strong Mechanical Aptitude
Analytical Problem-Solving and Critical Thinking
Unwavering Commitment to Safety and Protocols
Physical Stamina and Strength to Handle Demanding Work
Teamwork and Effective Communication
Ability to Work Effectively in a High-Temperature Environment
Strong Work Ethic and Reliability

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.

Relevant Fields of Study:

Manufacturing Technology
Industrial Maintenance
Metallurgy or Materials Science

Experience Requirements

Typical Experience Range: 2-7 years of experience in a heavy manufacturing or industrial environment.

Preferred:

Direct experience operating open-die or closed-die forging presses or hammers.
Proven experience in a hot work environment (e.g., foundry, steel mill, forge shop).
Demonstrable experience with die setup, tooling changes, and use of overhead cranes for heavy lifts.