R & D Metal Model Maker Tier 3 - 1st Shift

The Metal Model Maker 3 R & D uses innovative manufacturing techniques to create prototypes in an exemplary manner according to the company quality policies.

Qualified candidates will possess the following Minimum Requirements:

• High school diploma or GED
• Completion of an Associate’s Degree in Tooling & Manufacturing (or similar program) or a college-based Tool & Die or Technician Diploma or Certificate
• Working knowledge and training in Solidworks design and PDMworks for Management of files
• Four years of experience in the prototype or tool & die trade, specifically setting up and running tooling
• Experience training, teaching, and assessing other Prototype Metal Model Maker trainees in the apprenticeship program, working well and leading and mentoring in a team environment
• Skilled in all aspects of machine shop operations
• A valid driver’s license (and the ability to obtain a chauffer’s license)
• Ability to pass written and practical tests to obtain company hi-lo/forklift and crane license
• Ability to manage projects and resources effectively
• Proven mechanical inclination, general math and manufacturing knowledge, and trouble-shooting skills through standardized assessments
• Computer literacy
• Ability to lift 50 pounds
• Cannot have a pacemaker
• An excellent work record, including attendance
• Previous experience in a metal-forming manufacturing environment
• Experience leading other Prototype Metal Model Makers

(Minimum requirements are updated annually to meet the demands of various positions; employees hired prior to the latest revision update may not meet all current requirements.)

Essential Functions:

Leadership/Mentorship:

• Lead and mentor all Prototype Metal Model Makers on shift with the focus on Development projects.
• Assist Team Leader with scheduling and prioritizing Development projects. Work with other Metal Model Maker 3 leaders to set line-ups for shift and plan hand-offs.
• Effectively communicate with co-workers and management personnel to enhance teamwork and communication initiatives.
• Shares knowledge of work practices with Metal Model Makers, including the details of the designated Development build processes, thereby enhancing the overall project build process and improving the entire team’s throughput. Train new and existing employees on all aspects of Development and Prototyping, using Training Checklists as a guideline.

• Know tooling and capability run dates, and communicate any information that would prevent those dates from being met.

• Mentor new and existing employees in areas of needed skill development as appropriate to job duties and requirements.
• Provide necessary, accurate, and timely feedback of all pertinent information to co-workers and management, including training and validating/appraising work of other less experienced Metal Model Makers.

Die Development/Standard Practices:

• Apply tooling and troubleshooting knowledge to maintain machine uptime. Troubleshoot automatic and hand-feed presses.
• Perform de-burring of prototype parts, drilling holes, basic milling and surface grinding.
• Set up dies in hand-feed presses and load and unload components in hand-feed presses, Computer Numerical Controls (CNC) mills and lasers. Use proper die techniques to ensure tooling is robust and repeatable. Ensure tooling, gages, layouts and laser fixtures perform as expected, with no rework.
• Implement changes to form samples with thinning and hard mark areas. Address any simulation issues with the design team or Team Leader. Implement suggested changes and retest. Repeat until issues are resolved.
• Master and train others on other prototyping equipment and processes, including the Turret Press, CO2 Laser, Fiber Laser, CNC Machines, Welding and internal testing equipment.

Prototype Preparation/Record-Keeping:

• Process material for Development orders, including cutting coil stock and preparing blanks by getting it ready to run in the dies. Execute all aspects of the Development build process, leading the design process for prototype tooling, determining the manufacturing processes for prototypes using die logic comprehension. Build and assemble prototype tooling, communicating tooling requirements to the design team.
• Maintain R&D press room and machining areas making sure the machinery is kept clean and in working order. Maintain prototype and testing tooling and machinery, based on high-wear areas.
• Maintain inventory and organization of all die detail components and sensors within defined inventory locations; receive, relocate, and issue components from defined inventory locations.
• Record project time information in EAM daily including time on work orders and preventative maintenance. Keep project development information up-to-date, including process sheets, product characteristics, and subsequent issues.

Quality:

• Use and maintain quality tools such as calipers, micrometers, height gages, solid squares, pin gages, dial indicators, Joe blocks, 1-2-3 blocks, machine parallels, angle plates, sine plates, V-blocks, precision vices, protractors, feeler gages, radius gages, and telescoping gages.
• Use available quality data (Statistical Process Control, Coordinate Measuring Machine checks, fixtures, controls plans, and visual inspections) to verify that parts meet quality requirements.
• Validate process parameters and enter system deviations, when applicable.
• Verify tooling components for accuracy before use. Ensure that prototype parts produced are manufactured according to requirements including the initial layout of parts to print; document as needed per control plan.
• Implement and document corrective action plans for process and die build.
• Submit final prove-out prototype to Metrology lab for layout, and examine layout results and adjust tools as necessary.

Continuous Improvement/Lean Principles:

• Continuously improve development and design of tooling; document potential points of failure.
• Increase personal and departmental efficiency.
• Participate in and support lean initiatives, continuous improvement, and problem-solving events; document savings, consolidate processes, and eliminate operations.
• Identify and attempt to eliminate areas of waste.
• Anticipate problems and work to eliminate them before they happen.
• Follow up temporary fixes with permanent corrective actions.
• Participate in 8D or 5-Why problem solving teams, die improvements, and die reviews.

Safety/5S:

• Safely use hi-lo/forklift and cranes to load and transport dies, maintaining licenses and inspection sheets.
• Follow all safety procedures, including Personal Protective Equipment (PPE), controls, safety devices, lock-out/tag-out, use of coolants, and die block procedures.
• Identify potential safety issues and take appropriate action. Ensure environment is free of avoidable risks, and report concerns immediately, taking appropriate action to immediately rectify and resolve.

Organization/Communication/Professionalism:

• Effectively communicate with co-workers and management personnel to enhance teamwork and communication initiatives.
• Ensure prototypes are shipped within allotted hours according to customer designated delivery schedules.

• Pick up and deliver product to suppliers and customers, as needed. Provide assistance to suppliers, including on-site visits to their facilities, as necessary.

• Provide necessary, accurate, and timely feedback of all pertinent information to co-workers and management, including training and appraising the work of other prototype makers, as appropriate.
• Consistently exhibit appropriate attendance habits, working the hours necessary to perform the job.
• Organize and maintain efficiency of personal work area.
• Consistently adhere to, and support, company policies and procedures, including ISO, IATF 16949, and safety regulations.
• Accept instructions and duties in a positive manner.
• Treat all co-workers with dignity and respect.
• Exhibit all the attributes of a positive role model (including professionalism, personal integrity, and positive attitude) for employees and managers to emulate.
• Assist in maintaining company values (Integrity, People, Customers, Safety, We Can If…Do What It Takes, and Ownership) daily, through thoughts and actions.