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Forge and Hammer Operators run presses and hammers with several tons of force to pound, squeeze, or shape heated metals into desired shapes. Two types of dies are used in shaping. The open, flat die is used when only a limited quantity of forgings or large-size forgings are needed. The closed or impression die is used to produce large quantities of identical forgings.  

Job Duties  

Heavy Forgers may:  

Align and bolt dies into the machine  

Observe the color of the metal in the furnace to determine correct forging temperatures  

Start the machine and regulate the action of the hammer or press  

Position and turn the metal on the bottom die  

Verify the dimensions of the forging  

Drop-Hammer Operators may:  

Secure dies and position the workpiece on the lower die  

Press the pedal of the hammering machine causing the ram to strike the metal repeatedly  

Move the workpiece through a series of die impressions to attain progressively finer detail  

Turn knobs to regulate the speed and feed of the conveyor that automatically brings heated stock from the furnace  

The tools and equipment used may include:  

OCCUPATIONAL SPECIALTIES  

Forge & Hammer Operators may specialize in these areas:  

612.361-010 HEAVY FORGERS shape heated metal stock into forgings with power hammers or presses equipped with open dies.  

610.362-010 DROP-HAMMER OPERATORS set up and operate closed-die drop hammers to forge metal parts following work order specifications.  

611.482-010 FORGING-PRESS OPERATORS set up and operate closed-die power presses to produce metal forgings.  

611.662-010 UPSETTERS set up and operate closed-die forging machines equipped with a horizontal ram and gripping die to expand the end of hot metal bar stock.  

612.685-010 LEVER TENDERS  

611.685-010 PRESS OPERATORS tend presses and hammering machines. Their duties are generally limited to loading or feeding the press or hammer.  

611.685-014 HYDRAULIC OPERATORS tend hydraulic corrugating machines that corrugate (bend into folds) metal tubes used in making bellows.  

612.462-010 MULTI-OPERATION MACHINE OPERATORS set up and operate machines that automatically perform several operations such as roll-threading, upsetting, slotting, slitting, or shearing, to form metal chain or produce metal fasteners.  

612.462-014 NUT FORMERS set up and operate one or more automatic machines to shear, form, and punch nut blanks from hot or cold metal bar and coiled stock.  

612.260-010 FASTENER TECHNOLOGISTS set up and operate a variety of machines to forge, trim, drill, and tap metal stock to produce machine tools and form metal parts and fasteners such as screws, bolts, and nuts according to specifications.  

In addition to learning about these specialties, you may also find it helpful to explore the following MOIScripts:  

WORKING CONDITIONS AND REQUIREMENTS  

Forge and Hammer Operators may work independently or in crews of two to ten workers depending on the size of the workpiece and the type of machine operated. They may supervise manipulator operators, furnace tenders, helpers, laborers, and other crew members and generally work under the direction of forge shop supervisors.  

Shops are generally hot and noisy; however, many forge shops have heat deflectors and ventilating fans that reduce heat and smoke. Improvements in machinery have reduced noise and vibration. Forging occupations are more hazardous than most manufacturing occupations, safety training and required protective equipment have lessened the incidence of accidents.  

Most Operators work a standard 40-hour week and some may be required to work afternoon or night shifts. Overtime may be necessary and is usually compensated at the rate of time and 1/2. Operators who use face shields, ear plugs, safety glasses, or helmets generally receive protective equipment from employers.  

Most Operators belong to unions such as The International Brotherhood of Boilermakers, Iron Shipbuilders, Blacksmiths, Forgers and Helpers and The United Steelworkers of America. Union members are required to pay dues.  

You Should Prefer:  

• Activities dealing with things and objects  

• Activities of a routine, organized nature  

• Activities involving the use of machines, processes, or methods  

You Should Be Able To:  

• Repeat activities/tasks according to a routine procedure or sequence  

• Work within precise limits or standards of accuracy  

• Rate information using standards that can be measured or checked  

• Visualize objects in three dimensions  

• Notice slight differences in the shapes and shadings of forged objects  

• Demonstrate mechanical aptitude  

• Perform a variety of duties which may often change  

Math Problem You Should Be Able to Solve:  

The machine you are working on is set for a tolerance of 0.02. If the piece of metal you are working on is 0.67, how much do you need to adjust it to bring it in to tolerance?  

Reading Example You Should Be Able to Read and Comprehend:  

Should be able to read and understand terminology such as foundry mold, casting, slurry, and bond cope.  

Writing Example You Should Be Able to Produce:  

You should be able to write down the steps you go through in working with a piece of metal so that someone can take over for you when you go on vacation.  

Thinking Skill You Should Be Able to Demonstrate:  

You should be detail-oriented in examining a piece of metal and judging whether it meets specifications.  

EDUCATION AND PREPARATION OPPORTUNITIES  

NOTE: On-The-Job Training provided by the employer or a High School Diploma with specific Vocational Education Classes may qualify a person for this occupation.  

The following education and preparation opportunities are helpful in preparing for occupations in the MOIScript:  

***SCHOOL SUBJECTS***  

0700 CAREERS , 0900 COMMUNICATIONS , 2200 MATH , 2300 METALS , 3200 TECHNICAL DRAWING , 3300 TECHNOLOGY  

***VOCATIONAL EDUCATION PROGRAMS***  

049 MACHINE TOOL OPERATION/SHOP  

Approved vocational education programs in Machine Tool Operation and Machine Shop prepare students to shape metal parts on machines such as lathes, grinders, drill presses, milling machines, and shapers. Programs may also train individuals in the use of one machine. Instruction is given in calculating dimensions; using precision measuring instruments such as layout tools, micrometers, and gages; machining and heat-treating various metals; and in laying out machine parts.  

Courses in other trade and industrial programs may be required for completion of this program.  

High school students should consult their guidance office for more information about the specific requirements of this program at their school or area vocational education center.  

***POSTSECONDARY PROGRAMS***  

There are no Postsecondary Programs related to this MOIScript  

Search for a College and/or Instructional Program   

***APPRENTICESHIP OPPORTUNITIES***  

Although this occupation has apprenticeship programs available in Michigan, they are limited in number. See the Sources Of More Information below for name, address and phone number of the Bureau of Apprenticeship and Training.  

You will also find a more extensive list of information sources in the "What Is An Apprenticeship?" document found under the MOIS Supports Menu Items.  

***MILITARY TRAINING PROGRAMS***  

There are no Military Programs related to this MOIScript  

E-Learning Courses and Programs   

OPPORTUNITIES FOR EXPERIENCE AND METHODS OF ENTRY  

State and federal labor laws prohibit persons under age 18 from working with power-driven metal forming machines. Summer work in a forge shop as a sweeper or helper will give you an opportunity to observe the work and working conditions of Forge and Hammer Operators. Secondary vocational education programs in machine tool operation/shop may provide experience also.  

               School-to-Work opportunities include:  

informal apprenticeships  

mentorships  

job shadowing experiences  

touring a local Forge or Hammer Operator employer  

internships  

volunteer work with a Forge and Hammer Operator employer  

community service work with an agency  

To find a job as a Forge or Hammer Operator, apply directly to the personnel offices of industrial plants doing forge work. Assistance may be available from a local union or local office of the Michigan Works!. In addition, you should access and search the Internet's on-line employment services sites such as:  

Michigan Jobs & Career Portal

Michigan Talent Bank   

Classifieds Employment   

Yahoo! Careers   

Michigan Works!   

You should also enter an electronic resume on these on-line services.  

EARNINGS AND ADVANCEMENT  

Earnings of Forge and Hammer Operators depend on the size and type of employer, the worker's experience, and the size and type of forging machine operated. Those who operate high power or large capacity forging machines generally earn more than other operators earn.  

Nationally, according to limited data, the median weekly wage for forging machine operators was $602 or $15.05 per hour in 1998.  

In Michigan, production workers in the metal forging and stamping industries, where most Forge and Hammer Operators are employed, had average hourly wages of $20.54 in 1998.  

The base hourly wage rates for most unionized Forge and Hammer Operators in the automobile industry in 1999 ranged from $19.85 to $21.25.  

These workers received a cost-of-living allowance. Some employers also provide extra pay for late-shift work.  

Depending on the employer, most Forge and Hammer Operators receive paid vacations and holidays; life, accident, disability, and hospitalization insurance; retirement plans; and sick pay. Some workers and their dependents may also receive dental and/or optical benefits.  

Forge and Hammer Operators usually begin as helpers on forge and hammer crews. Advancement to higher level jobs such as Heavy Forge and Hammer Operator requires several years of on-the-job training and experience. Promotion to a limited number of supervisory positions generally depends on the individual's knowledge of machine shop technology and supervisory abilities.  

EMPLOYMENT AND OUTLOOK  

Nationally, the number of Forge and Hammer Operators employed is unknown. Employment of Forge and Hammer Operators is expected to decline through the year 2006.  

The influx of foreign manufactured products, including motor vehicles, and the foreign outsourcing and/or offshore production of parts (such as auto engines, transmissions, and transaxles) by domestic manufacturers are expected to result in fewer employment opportunities for Forge and Hammer Operators. Furthermore, the growing use of new materials, such as advanced ceramics and plastics, in aircraft, motor vehicles, home appliances, office equipment, structural materials, and electronic devices, will lessen the demand for metal forgings.  

There were approximately 4,650 Forge and Hammer Operators employed in Michigan. All worked in the manufacturing industry.    

Employment of Forge and Hammer Operators is expected to decline through the year 2005. About 70 annual openings will occur to replace workers who retire or transfer to other jobs or occupations, although most of these will be filled by experienced workers who have been laid off. The employment of Forge and Hammer Operators is expected to decline because improved forging techniques and equipment will result in greater output per worker. Because employment in some forge shops is sensitive to changes in economic conditions, employment of Forge and Hammer Operators may decrease further during recessions.  

MICHIGAN'S EMPLOYMENT OUTLOOK TO 2005  

SOURCES OF ADDITIONAL INFORMATION  

Printed Occupational information is available upon written request from sources below.  

SUMMARY PROFILE  

The occupation of Forge and Hammer Operator can be summarized by the following:  

MOISCRIPTS are Copyright 2003, Michigan Department of Career Development