Metal Finisher II

As a Metal Finisher, you will hold a very important role in the Kings Mountain Operations (KMO) facility. In this role, you will inspect fabricated and welded Mack MRU TerraPro cab assemblies for surface, hole, weld, threaded-feature, fit, and workmanship defects. This is a hands-on repair position. The role performs approved welding, stud-weld dent pulling, metal straightening, thread and hardware repair, grinding, blending, and surface finishing; verifies the completed repair; documents findings; and escalates defects that exceed the released repair standard, employee qualification, or Quality and Engineering disposition limits.

Duties/Responsibilities:
•    Inspect each assigned cab using direct light, reflected light, sight-line viewing, and hand-feel techniques to identify defects that may remain visible after paint.
•    Detect and repair allowable dents, dings, ripples, waves, oil-canning, creases, high and low spots, flange distortion, and handling or fixture marks.
•    Verify winking holes, access holes, pierced holes, slots, and mounting features for correct location, shape, opening, alignment, and freedom from obstruction.
•    Inspect weld nuts, studs, and threaded features for missing hardware, damaged or contaminated threads, cross-threading, incomplete engagement, loose or spun weld nuts, and incorrect location or orientation; repair threads or remove and replace hardware by an approved method.
•    Check visible welds for missed or short welds, cracks, porosity, undercut, burn-through, blowholes, excessive weld buildup, sharp projections, and weld spatter.
•    Check panel, bracket, reinforcement, hem, flange, and joint conditions for alignment, gap, flushness, distortion, interference, or missing components.
•    Remove approved burrs, sharp edges, weld spatter, minor surface contamination, adhesive residue, and localized scratches or gouges that can be corrected within the established repair standard.
•    Perform approved GMAW or MIG and other assigned weld repairs in accordance with the released weld procedure, specified parameters, and visual acceptance criteria.
•    Use stud-welding dent-repair equipment to attach pulling studs, pins, or approved pulling media; use a slide hammer, bridge puller, or other approved pulling tool to restore panel contour; then remove the temporary studs and grind or blend the area flush without thinning or damaging the parent metal.
•    Straighten and metal-finish damaged areas using body hammers, dollies, spoons, files, grinders, sanders, and other approved tools while protecting adjacent surfaces and features.
•    Repair or replace approved weld nuts, studs, small brackets, and other welded attachments; verify location, orientation, weld quality, and thread function after repair.
•    Dress and blend completed weld repairs to the required contour while preserving required weld size, sheet thickness, structural integrity, and corrosion-protection requirements.
•    Re-inspect repaired areas from multiple angles and confirm that the surface contour, feature function, and workmanship meet the applicable visual standard, drawing, work instruction, or quality alert.
•    Identify recurring defect patterns and communicate the cab location, defect type, probable source, and frequency to the Team Leader, Production Supervisor, Quality, and Engineering.
•    Record defects and repairs in the designated tracking system or inspection sheet and maintain traceability to the cab when required.
•    Support containment, first-piece checks, layered audits, standardized work updates, and continuous-improvement activity within the BIW area.
•    Maintain tools, lighting, gauges, consumables, and the work area in a safe, clean, and ready condition.

Repair Limits and Escalation: 
•    Use only approved repair methods, specified tools, and authorized consumables.
•    Perform only the welding processes and repair operations for which the employee has completed required training and demonstrated qualification.
•    Follow the applicable weld procedure and specified wire, shielding gas, machine settings, joint preparation, weld size, sequence, and finishing requirements.
•    Do not alter a safety-critical, structural, datum, locating, or engineered feature unless the Engineering and Quality teams specifically authorize the work.
•    Obtain Quality or Engineering direction before nonstandard component replacement, hole relocation, heat application, structural straightening, or any repair that may change cab geometry or design intent.
•    Stop work and notify the Team Leader or Production Supervisor when the defect cannot be corrected within takt or standard repair time, recurs on multiple cabs, creates a safety risk, or may affect fit, function, corrosion protection, or regulatory compliance.
•    Segregate or identify nonconforming material as required and obtain Quality or Engineering disposition before release when acceptance criteria are unclear.

Required Qualifications (Education, Skills, & Experience):
•    Ability to visually identify subtle metal-surface and assembly defects under production lighting and confirm findings by touch or approved gauge.
•    Ability to safely set up and operate assigned GMAW or MIG welding and stud-welding equipment and produce controlled, repeatable repairs on thin-gauge cab sheet metal.
•    Ability to use stud-welded dent pullers, slide hammers, bridge pullers, body hammers, dollies, grinders, sanders, and related metal-finishing tools without creating secondary damage or excessive metal thinning.
•    Ability to evaluate repaired welds for location, size, fusion, profile, porosity, cracks, burn-through, undercut, spatter, and final surface condition.
•    Ability to read and follow standardized work, visual acceptance standards, quality alerts, repair instructions, and basic drawings or feature-location references.
•    Ability to distinguish a standard in-scope weld or metal repair from a condition requiring Quality, Engineering, Maintenance, or specialized repair support.
•    Ability to document defects clearly and communicate effectively with Production, Quality, Maintenance, and Engineering.
•    Completion of required KMO training and demonstrated qualification for each assigned inspection or repair method.

Preferred Qualifications (if applicable):
Prior experience in Body in White, automotive or heavy-truck fabrication, thin-gauge GMAW or MIG welding, stud-weld dent repair, metal finishing, collision or body repair, dimensional inspection, or manufacturing quality is preferred. Experience repairing weld nuts and studs and using defect standards, gauges, and structured problem-solving methods is also beneficial.

Physical Requirements:
•    Regularly required to lift and carry components weighing up to 50 lbs.; team lift or equipment used for heavier items.
•    Must be able to safely push, pull, and maneuver parts and materials on the production line as required to perform job responsibilities.  
•    Regularly required to bend, reach, crouch, and use hand tools. 

Work Environment/Conditions:
•    Regular exposure to loud noise, moving mechanical parts, and occasional exposure to fumes, dust, or extreme temperatures.
•    Exposure to sheet metal, welding operations, and airborne particles.
•    Frequent standing, walking, bending, stooping, climbing, and reaching.
•    Schedule may include early morning, evening, or weekend shifts based on production needs. Overtime may be required during high volume periods.
•    May be designated as essential personnel during plant operational disruptions, planned shutdowns, or emergencies.