Department: Quarry Operations
Reports To: Crusher Supervisor or Quarry Manager
Work Location: Quarry and aggregate processing plant
Schedule: Assigned day or night shift; overtime and weekends as production requires
Position Summary
The Crusher Plant Operator is responsible for safely operating and monitoring the jaw crusher, cone crushers, screens, conveyors, feeders, and related equipment. The operator keeps material moving through the plant, helps produce aggregate that meets specifications, identifies equipment problems early, and communicates production and maintenance needs to the crew.
Primary Responsibilities
Plant operation and production
- Complete a pre-shift walkaround of the plant, including crushers, screens, feeders, conveyors, transfer points, guards, walkways, and emergency stops.
- Start and shut down equipment in the established sequence, confirming that personnel are clear and equipment is ready before startup.
- Monitor jaw crusher feed and discharge to identify oversized rock, bridging, plugging, or uneven feed.
- Monitor cone crusher operation, including feed level, motor load, lubrication and hydraulic system indications, unusual noise, and vibration.
- Monitor screen performance and material flow to identify blinded or damaged media, buildup, carryover, and changes in product sizing.
- Adjust feeders, crusher settings, and other plant controls only within approved procedures and the operator’s training and authority.
- Coordinate with loader and haul truck operators to maintain steady feed and avoid overloading or starving the plant.
- Watch conveyors and transfer points for belt tracking issues, spillage, plugged chutes, and material buildup.
- Work with the supervisor and quality control personnel to meet production targets and product gradation requirements.
Inspections and maintenance support
- Recognize and promptly report abnormal temperatures, pressures, vibration, leaks, wear, noise, or changes in crusher and screen performance.
- Document defects and communicate the urgency and location of needed repairs to the supervisor and mechanics.
- Assist with routine cleaning, screen changes, wear-part inspections, and planned maintenance when trained and assigned.
- Keep platforms, stairs, access routes, and work areas clean and free of unnecessary material buildup.
- Verify that guards and safety devices are in place before equipment is returned to service.
Safety
- Follow company procedures and applicable MSHA requirements at all times.
- Use required personal protective equipment and maintain awareness of mobile equipment and other personnel around the plant.
- Follow lockout/tagout and verification procedures before entering, cleaning, inspecting, or working on equipment where hazardous energy or unexpected movement could cause injury.
- Never reach into operating equipment, clear a blockage, or bypass a guard while equipment is energized.
- Stop work and notify supervision when an unsafe condition, equipment failure, or uncontrolled hazard is identified.
- Participate in pre-shift meetings, workplace examinations, training, and incident reporting.
Reporting and communication
- Record production totals, operating hours, downtime, reasons for delays, inspections, and maintenance concerns accurately.
- Communicate plant status, changes in material quality, equipment issues, and outstanding work during shift handoff.
- Keep the crusher supervisor informed when production falls behind target or product appears out of specification.
Qualifications
- Prior experience operating a crushing and screening plant preferred; experience with jaw and cone crushers is strongly preferred.
- Working knowledge of aggregate production, material flow, crusher operation, and basic mechanical troubleshooting.
- Ability to understand equipment gauges, alarms, control panels, and written operating procedures.
- Ability to communicate clearly with supervisors, mechanics, loader operators, and quality control personnel.
- Ability to complete inspection and production records accurately.
- Willingness to complete required site-specific and MSHA training.
Physical and Work Requirements
- Work outdoors in varying temperatures and weather conditions around dust, noise, vibration, and heavy equipment.
- Regularly walk the plant, climb stairs and ladders, and access elevated work platforms.
- Perform physical tasks associated with inspections and housekeeping, with appropriate tools and assistance.
- Work assigned shifts, including nights, weekends, and overtime when required.
Performance Expectations
The Crusher Plant Operator is expected to operate the plant safely, maintain consistent material flow and product quality, provide accurate shift information, and report developing equipment problems before they result in avoidable downtime or damage.