The Senior Machinist is a highly skilled, lead-level manufacturing professional responsible for the setup, operation, and maintenance of CNC and manual equipment including vertical milling machines, press brakes, and plasma cutting systems. This role serves as a technical resource for the shop floor, ensuring parts are produced to engineering specifications with a strong emphasis on quality, precision, and on-time delivery. The Senior Machinist is expected to mentor junior machinists, support continuous improvement initiatives, and uphold all applicable quality and safety standards.
Essential Duties & Responsibilities
CNC & Manual Machining
- Set up, program (conversational or G-code), operate, and troubleshoot CNC vertical machining centers (VMCs) and manual mills to produce precision components per engineering drawings and tolerances.
- Perform first-article inspections and in-process dimensional verification using precision measuring instruments (calipers, micrometers, CMM, height gauges, bore gauges).
- Select appropriate tooling, speeds, feeds, and fixturing for efficient and accurate material removal across a variety of metals (steel, aluminum, stainless, titanium, and alloys).
- Interpret and work from GD&T-annotated engineering drawings, work orders, and traveler packages.
Press Brake Operations
- Set up and operate CNC and manual press brakes to form sheet metal and plate components per specified bend sequences, angles, and tolerances.
- Select tooling (punches and dies) and program bending sequences; verify springback compensation and material allowances.
- Perform first-piece checks and in-process inspection to ensure dimensional compliance on formed parts.
- Maintain die sets and tooling inventory; inspect for wear and report deficiencies.
Plasma Cutting Operations
- Set up and operate CNC plasma cutting tables and hand-held plasma systems for profile cutting of ferrous and non-ferrous materials.
- Load and nest cut programs; adjust amperage, standoff height, and feed rates to optimize cut quality and minimize HAZ (heat-affected zone).
- Inspect cut parts for dimensional accuracy, edge quality, and conformance to drawing specifications.
- Perform routine maintenance on plasma cutting equipment including consumable replacement (tips, electrodes, shields) and water table upkeep.
Quality & Documentation
- Complete all required production travelers, inspection records, and non-conformance reports (NCRs) in accordance with the quality management system (QMS).
- Participate in first-article inspections (FAI), in-process audits, and corrective action activities as needed.
- Maintain awareness of and compliance with applicable customer requirements, specifications, and applicable regulatory standards.
Mentorship & Team Leadership
- Provide on-the-job training and technical guidance to machinist apprentices, machinists, and setup operators.
- Assist with workload planning and job sequencing to support on-time delivery goals.
- Communicate effectively with engineering, quality, and production planning to resolve technical issues and disposition non-conforming material.
Safety & 5S / Housekeeping
- Follow all company safety policies, OSHA regulations, and PPE requirements at all times.
- Maintain work area in accordance with 5S standards; participate in shop floor organization and improvement activities.
- Identify and report unsafe conditions, near-misses, and equipment malfunctions to supervision immediately.
Qualifications
Education & Experience
- High school diploma or GED required; completion of a formal apprenticeship program, trade school, or associate degree in machining technology strongly preferred.
- Minimum 5 years of hands-on machining experience, with at least 2 years in a senior, lead, or setup machinist capacity.
- Demonstrated experience operating CNC vertical milling machines, press brakes, and plasma cutting equipment in a production environment.
Technical Skills
- Proficient in G-code/M-code programming and conversational CNC controls (Fanuc, Haas, Mazak, or equivalent).
- Strong ability to read and interpret engineering drawings, GD&T, blueprints, and work order documentation.
- Proficient with precision measurement instruments including micrometers, calipers, height gauges, protractors, and angle finders.
- Working knowledge of material properties and machinability of common metals and alloys.
- Familiarity with CAM software (Mastercam, Fusion 360, or equivalent) a plus.
Knowledge, Skills & Abilities
- Strong problem-solving skills with the ability to identify root cause and implement corrective action on machining and forming defects.
- Detail-oriented with a commitment to producing high-quality work within specified tolerances.
- Ability to work independently and prioritize tasks in a fast-paced production environment.
- Effective verbal and written communication skills; ability to document work clearly and accurately.
- Demonstrates a professional, team-oriented attitude and a willingness to mentor and develop others.
Physical Requirements
The following physical demands are representative of those required to successfully perform the essential functions of this position:
- Ability to stand, walk, and work on concrete floors for extended periods (up to 10 hours per shift).
- Frequently lift and/or move materials, tooling, and fixtures weighing up to 50 lbs; occasionally greater weights with mechanical assist or team lift.
- Manual dexterity required for precision hand tool use and machine operation.
- Exposure to machine noise, coolant fluids, cutting oils, metal dust, and UV/IR radiation from plasma cutting operations; appropriate PPE required.
- Vision requirements: ability to read measuring instruments, engineering drawings, and CNC displays; color distinction may be required.
ND Defense is an equal opportunity employer including disability and veteran.
