This position involves the use of manually controlled machine shop equipment primarily including the Engine Lathe, Bar Lathe, Milling Machine, Commutator Undercutting Machine, Horizontal Turret Lathe, Vertical Turret Lathe, OD Grinder and incidental use of other machines such as the Drill Press and Tool Grinding and Sharpening equipment.
Depending on the operation, material comes in many different forms including purchased castings primarily made of aluminum, nodular iron, cast steel, brass and bronze, bar stock primarily made of steel and stainless steel, composite materials, armatures from the press room and stators from the winding room.
OD turning on parts such as stators, armatures, and rotors plus associated shaft straightening operations. ID turning on parts like bearing caps - plus various threading, boring, and drilling operations.
Turning various medium and small parts from bar stock.
Expert in setting up and operating manual horizontal turret lathes, especially turning castings to tight tolerances. Diameters to 20 inches and larger.
All types of cutting and facing operations including cutting the keyways on all shafts.
Commutator Under Cutting Machine:
Undercut and smooth out the commutator for DC motors.
Horizontal Turret Lathe:
OD and ID turning and boring on bearings, brackets, motor frames, bearing caps, bushings, bar stock and composite materials.
Vertical Turret Lathe:
Boring and turning operations on parts such as stators, stator boards, motor covers and deflectors. Boring is usually for concentricity - turning is often for "locating rabbits" and to cut parts to proper height.
OD Grinder: Grinding shafts to final dimensions.
Performs other duties as assigned by supervisor.
Level 1: Setup - Operation - Maintenance - Has attained very high level of proficiency and requires very limited supervision. Generally has a minimum of 6 years experience. Can perform any operation that the machine is capable of doing. Can set up any sequence of operations using any combination of tools with no outside help. Determines all speeds and feeds and is a competent tool sharpener. Is extremely proficient at math required by job - is expert at using measuring instruments such as micrometers and other gauges. Performs routine cleaning and maintenance of machine including checking oil sight glasses. Can determine when it is necessary to call Maintenance to return the machine to normal operating condition.
Quality/Continuous Improvement/Productivity - Inspects own work - has very low rejection rate. Uses experience and proven techniques to pass job on to next work station in optimum time to maintain required quality and minimize rework. In general the jobs require close tolerances - keeps track of dimensional requirements during entire machining operation. Represents Machine Shop on Continuous Improvement Task Teams. Assists Machine Shop Supervisor in establishing Certification Test for each machine. Assists new employees and other Technicians with honing skills necessary to obtain Certification. Works closely with Engineering on prototype work and makes meaningful suggestions for product improvement.
Problem Solving - Can work out virtually any problem that arises concerning work being performed - has usually seen some form of the problem before.
Blueprints & Traveler - Can not only correctly interpret the blueprints, but can assist other Technicians. Can interpret all operations listed on Traveler documents that move with each job.
Job requires standing most of the day. There is some repetitive motion, such as cranking both the Vertical and Horizontal Turret Lathes, but in general, the manual operations required are independent of each other. Since overhead cranes are available in all work areas, Technicians are not required to lift more than 50 pounds.
Environmental / Safety Issues
Normal exposure to coolant liquid, dust and fumes - limited exposure to hazardous materials. Keeps work area clean and free of scrap materials. Follows all safety rules applicable to machine as stated on posted signs and in Company policy.
Cross trains on all of the machines listed in this position description as directed by the Machining Supervisor.
Requirements for this position are to also be engaged in: 5S, Continuous Improvement, On-Time Delivery, Routine Total Preventative Maintenance and the submission of Improvement Ideas.
Education / Certification
High school graduate preferred - will consider commensurate experience. Has passed Certification Test established by the Company for each machine that is used without close supervision.
Class A machining skills, manual and CNC a plus. CNC programming skills a plus. Experience in Total Productive Maintenance or Lean Manufacturing a plus.
Ensures that finished product meets specifications and that it is moved to the next position on the Traveler in a timely manner.
Chain of Command
Reports to Machining Supervisor. Ensures that the Machining Supervisor is informed of all progress and problems.
All Positions at WARD LEONARD require access to information or technology that is subject to the International Traffic in Arms Regulations (ITAR) and other US government security regulations. These laws do not permit access rights to non-US Citizens or to other unauthorized individuals. Therefore, presently all applicants must be US Citizens and comply with ITAR requirements for access rights to be considered for a position.