JOB SUMMARY:Sets up completely and independently and operates thread rolling machines at highest level of complexity to roll threads, grooves etc. on external surfaces of various types of metal workpieces to required tolerances per blueprint or other specifications. Performs complex die pocket adjustments for multiple diameters rolls and grooves including etching dies and adjusting multiple dies. Troubleshoots or reworks problems with product, machinery or machines and makes necessary repairs to machines. Operates threadrolls at highest speed and consistently performs significantly above job productions standards including setup time and good quality pieces produced.
DESCRIPTION OF ESSENTIAL FUNCTIONS AND RESPONSIBILITIES:
Completely and independently with little or no supervision or review performs the following. Other duties may be assigned as required by Company requirements.
Sets up thread rolling machine to highest levels of complexity making required adjustments to dies, groove depths, etc. to tolerances of ± .0001. Uses various support tools and equipment such as wrenches, pliers, calipers, micrometers, gages, tri-rolls, thread wires, thread limit gages, etc. to set-up, maintain and repair machine. Modifies or adapts dies and other tooling in order to get most effective set-up. Able to use shims in any manner required. Troubleshoots or reworks any problems and makes necessary repairs to machines.
Loads workpieces, positions and secures to holding device keeping proper clearance for parts. Verifies workpiece position. Selects feed rate, timing, tooling, stops, etc. and other variable tasks and items based upon most efficient methods to maintain tolerances for material and tooling required. Adjusts for various pitch diameter. Performs any required die stacking and die pocket adjustments for size.
Operates the thread rolling machines as required for the completion of the various operations necessary on the workpieces being machined. Maintains visual check of work in progress to assure proper functioning of equipment. Conducts first part production run to ensure alignment. Etches parts to check for mismatches of threads and grooves or defects. Consistently performs significantly above job production standards including setup tome and good quality pieces produced.
Provides necessary counts, processes documentation correctly, and maintains daily production logs using computer software applications or production worksheets. Applies SPC as required. Keeps interim records for subassemblies, material, tooling, rework, etc. while in the cell.
Reads and interprets blueprints or other documentation to visualize machining required and plans sequence of operations.
Works as an active team member by participating in problem solving, team building, and all other team activities to improve the processes, productivity, quality, etc. of the production operations in a cell. Uses interpersonal skills as well as good written and verbal communications. Assists other cell members as required
Equipment/Process Responsibilities -Performs duties where property, tools, equipment or machines may be damaged, or man hours lost through improper daily maintenance or attention to processing. Sets up and calibrates a minimum of 2 thread rolling Machines to the highest levels of complexity for the jobs performed. Maintains and effects minor repairs of machines. Threading machines may be vertical or horizontal.
Material or Product Responsibilities -Performs duties that require close attention to work and supporting documentation specifications and other requirements. Responsibility for accuracy of parts machined. Visually and/or with measuring instruments, checks work performed for proper results. Must threadroll titanium, enconel and steel.
Responsibility for Work of Others -Accuracy of communication is mandatory to the successful production and qualification of workpieces. Must communicate to appropriate personnel any problems or concerns regarding quality of work received or time flow of work in progress as it affects production schedules. Must be able to train employees of equal or lower classification in thread rolling machine set-up and operation as well as on methods and procedures used by the Company in the production workflow and tracking.
Safety Responsibilities -Good housekeeping, knowledge of good machining safety is necessary.
Initiative and Ingenuity- Requires initiative in solving problems associated with the highly complex die set-up and operation of various thread rolling machines concurrently and uses ingenuity in adapting shims and other shop aids to complete machining operations. Makes suggestions for improving the efficiency of workflow or equipment operation. Takes on or reports for additional work as current tasks are completed. Performs other work-related tasks as deemed necessary by Company needs.
WORK ENVIRONMENT
Environmental Surroundings -Work is in a machine shop environment where noise, temperature fluctuations, the repetitive nature of job, etc. are less desirable than in a typical office environment.
Unavoidable Hazards- Possible hazards related to cuts, bruises, finger and "hand injuries and muscle strains. Exposure to metalworking fluids and airborne particles. Protective equipment and clothing appropriate to the task at hand is required.
EFFORT
Physical- Able to lift up to 50 pounds. Requires strength to adjust requisite equipment to set-up specifications. Hand and finger manipulation. Able to reach, bend and stretch. Able to use tools required for machine set-up which may be fatiguing and require extensive physical exertion for extended periods of time. Capable of maneuvering between and operating at least 2 Thread Rolling machines concurrently. Most job assignments require standing and/or sitting for periods exceeding 15 minutes at a time.
Mental- Work at times is highly repetitive and monotonous. However, set-up and/or machine repair is varied and may require improvisation and ingenuity. Reasoning ability required to interpret complex blueprints and documentation of a highly technical nature. Must be able to draw valid conclusions from a variety of abstract and concrete variables. Required to run at least 2 thread rolling machines concurrently and be able to organize workflow for best efficiency.
Visual- Close attention to detail with moderate eye concentration over long periods of time. Able to read various precision instruments such as micrometers, calipers, gauges, comparator, etc. Must be able to visually check workpieces for quality.
