Prototype Machinist Moderate

Supervisory Responsibilities: None

Purpose:  To build and machine Prototype components to the specifications required, while working in close collaboration with the Engineering Department and Production Departments.  Assists in training for Entry and Intermediate level Prototype Personnel.

Essential Duties/Responsibilities: 

• Ensure a safe work environment for self and others.  Follows all safety rules and regulations. Demonstrate commitment to safety program.
• Studies blueprint to determine machining needs, plans layout, and understands best plan for assembly for making recommendations
• Studies and understands preliminary blueprints, specifications, recognizes manufacturing problems and cost reduction ideas and confers with Engineering and Shop personnel to act on these problems early on in new designs
• Setting manufacturing processes for prototype and production environments.  Understands cutting forces and the effect on parts and fixturing.  Demonstrates this in the processing of parts with proper tool selection, tool path, tool sequencing, and fixture design to establish an effective and efficient process while maintaining close dimensional tolerances
• Involved with the Advanced Quality Planning teams.  Works as a team player to identify manufacturing problems, cost reduction ideas, and solutions
• Proficient at operating and set up/programming the following equipment:  helical gears in the CNC hob, G code lathes and mills (programming skill at an advanced level, good understanding of cutting compensation, work coordinate system, and 4th axis mill work)
• Proficient at operating the following equipment:  tool and cutter grinder, cylindrical grinder (capable of grinding outside and inside diameters and tapers) (moderate level)
• Proficient at trouble shooting involute, lead, and run out problems on the hob
• Proficient at inspecting helical gear and spline involutes on the M & M Involute inspection equipment
• Able to design and fabricate moderate level hydraulic and pneumatic fixtures for prototype and production processes.  Understands the effect of cutting forces on the part and fixture, and demonstrates this in the fixture design
• Sets up broaching machine for broaching spline with little or no trouble at all, at advanced level
• Sets up shaper machine for shaping internal or external gears or splines with little or no troubles at all, at advanced level
• Sets up roll forming machine for cold forming external splines with little or no troubles at all, at advanced level
• Understands spline data, whether it's pilot diameter for broaching, pre-roll diameters for cold forming and the effect heat treat will have on splines.
• Understand spiral and hypoid bevel and straight bevel gears processes and manufacturing operations that confer with roll testing patterns
• Evaluates tooling orders received to determine whether tooling should/can be manufactured in-house or procured from outside vendor and processes parts with proper allowances (grind stock, plating allowance, pre-roll diameters, etc.)
• Calculates and records tool requirement data carefully in order to promote continual process improvement
• Tests assembled mechanisms for fit and function and able to find the source of any problems found
• Involved with AQP meetings.  Able to study blueprints and assembly drawings, recognize manufacturing problems and cost reduction ideas.  Works well with the team to brainstorm solutions
• Demonstrates coaching abilities in the workplace
• Demonstrate leadership and commitment to quality initiatives
• Understands programs and what the program is doing to part
• Maintains a clean and organized work area and safe shop environment
• Performs preventive maintenance to shop equipment
• Demonstrate commitment to the TEAM Industries Quality Management system and Objectives
• Promote a positive atmosphere.  Actively support activities that promote the welfare and morale of TEAM employees.
• Will be required to perform other duties as requested, directed or assigned.

Minimum Requirements: 

    Education & Experience:

• Two-year technical degree preferred
• Six to ten years related experience and/or training; or equivalent combination of education and experience

Job Knowledge, Skills and Abilities:

• Must posses knowledge of tolerancing, including GD&T, to have ability to explain to co-workers, operators, or others
• Must be proficient in all skills of Prototype Machinist-Intermediate Level
• Must be proficient in AutoCad to layout programming points (moderate level)
• Thorough knowledge of heat treating process
• Must posses advanced knowledge of proper cutting tool selection and cutting speeds and feeds
• Must posses working knowledge of geometry and trigonomety relationships and principles
• Must be proficient in application and understanding of algebraic equations and relationships
• Must have ability to train Entry and Intermediate Level Prototype Machinists in the basics to include operation of:  surface grinder, saws, Sunnen hone, gragramming of  tool room lathes, tool room mills, CNC hob, and G code lathes and mills, involute inspection equipment, shaper machine, cylindrical grinder, broaching machine, roll form machine
• Regular attendance required

Training:

• AutoCad
• Product View
• Microsoft Office Products
• Virtual Gibbs CAM
• Reference OJT

Physical Demands:

• Ability to lift 50 pounds
• Walking or standing up to 75% of shift

See Functional Job Description for complete demands