Tool Maker

PRIMARY JOB OBJECTIVE:

Applies knowledge and experience to provide support by operating a variety of Tool Room equipment to produce various types of tooling with a high degree of quality and workmanship.

ESSENTIAL JOB FUNCTIONS:

• Capable of proficiently setting up and operating Tool Room machines, both CNC and manual, to produce new or rework tooling to exacting tolerances and specifications.
• Assists production, maintenance, and engineering staff to resolve tooling-related problems.
• Capable of reading blueprints.
• Responsible for the inspection of tooling to ensure quality and conformity.
• Uses various gauging equipment, mics, calipers, scales, indicators, comparators, bore gauges, gauge blocks, sine bars, etc.
• Ensures smooth workflow of projects throughout the department and maintains quality of workmanship.
• Requires working to close tolerances.
• Performs layout and assembly work required to construct tools, dies, gauges, machine parts, jigs, and fixtures.
• Analyzes tooling specifications and plans work using knowledge of tool designs, shop mathematics, machining, and layout and assembly procedures.

QUALIFICATIONS:

• High school diploma or GED equivalent.
• Must be able to read, write, use shop math, understand tool room terminology, and read blueprints.
• Must have knowledge consistent with skills required to perform the job responsibilities outlined in the ESSENTIAL JOB FUNCTIONS section.
• Able to lift 80 pounds, push/pull 200 pounds, lift, bend, stoop, climb, reach, and position items being worked upon.
• Must have good vision and hearing.
• Able to work with both hands.

SKILL LEVELS:

Individuals must demonstrate their abilities for each grade. When an employee can confidently and competently complete all the requirements in their current grade, they shall be promoted to the next grade. The employee is not required to perform all the tasks of the grade higher than their current stature. The grades listed below are not all-inclusive and can be changed at any time.

Apprentice:

• The apprentice tool maker must be able to perform the following:
  • Strong math skills.
  • Must have good mechanical aptitude.
  • Experience working with hands – Shop class, mechanic, farming, etc.
  • Needs to have a minimum of the following tools: 0-1 micrometers, 0-6 calipers, edge finder, protractor, indicator & stand, ball pen hammer, 12” combination square, scribe, wrenches up to ¾”, screwdriver set, and scientific calculator.
  • Some basic computer skills.

Grade 5:

• The tool maker must be able to perform the following:
  • Must be proficient in the use of measuring instruments, including micrometers, calipers, scales, and indicators.
  • Process Improvement Request.
  • Be able to use TMS to find work orders and effectively record daily labor.
  • Sam Dong Ohio, Inc. Quality Philosophy.
  • Emergency Guidelines.
  • Daily paperwork/Labor reporting.
  • Machine tool function.
  • Steel marking and identification.
  • Material characteristics – hardness, magnetic, ease of machining.
  • Tool tower operation.
  • Fraction to decimal conversion.
  • Tap drill sizes: How to use charts, where to find them.
  • Able to pull up blueprints for tooling on the P.C.
  • Operate cranes in the department.
  • Maintains appropriate tools and keeps current on calibration.

Grade 4:

• The tool maker must be able to perform all tasks in Grade 5, plus the following:
  • Bridgeport Mill.
  • Cutoff Saw.
  • Use comparator to qualify parts, including angles and radii.
  • Extrude hone to polish/maintain extrusion dies and draw dies.
  • Surface grinder.
  • Drill sharpeners.
  • Brown & Sharpe form grinder.
  • Rockwell tester.
  • Vertical band saw.
  • Surface finish tester.
  • Manual lathe-turn/Bore diameters.
  • Control of non-conforming product.
  • Thread identification.
  • Build/maintain CNS work roll assemblies.
  • Remove scrap carbide from work-roll shafts.
  • CNS Back-up roll procedure CNS-031-06.
  • Operate the Tschudin CNC Grinder.
  • Operate the Studer CNC Grinder.
  • Build coining roll assemblies.

Grade 3:

• The tool maker must be able to perform all the tasks in Grades 5 and 4, plus the following:
  • Operate the Elox wire EDM.
  • Operate the Hitachi Seiki 25 CNC lathe.
  • Operate the Hitachi Seiki 40 CNC lathe.
  • Operate the Shibaura Horizontal Mill.
  • Fabricate replacement components for production as needed.
  • Manual lathe OD/ID threading.
  • Makes recommendations to continuously improve tool designs.
  • Able to use AUTO-CAD to modify existing blueprints.
  • Perform machining from blueprints, detailed specifications, duplicate parts, or verbal instructions.
  • Capable of working with varied ranges of ferrous and non-ferrous materials.

Grade 2:

• The tool maker must be able to perform all the tasks in Grades 5, 4, and 3, plus the following:
  • Set up and program both the Charmilles and the Elox-Fanuc wire EDM Machines.
  • Tschudin CNC grinder set-up/operate.
  • Studer CNC grinder set-up/operate.
  • Knowledge of machine tools, including their design, uses, and maintenance.
  • Works with engineering and can decide if a job is within our in-house machine capabilities. If not, can make recommendations as to the equipment needed to perform the work.
  • May act as a lead on given tooling projects by interacting with engineering or production and coordinating tool room activities in the construction and repair of new and existing tooling.
  • Selects metals to be used from a range of metals and alloys based on properties such as hardness, wear, and heat tolerances.
  • Inspects/troubleshoots equipment, tooling, or materials to identify the cause of errors or other problems/defects and recognizes the tooling’s impact. Is then able to estimate timelines for resolution.
  • Proficient in the use of AUTO-CAD to create new blueprints.
  • Ability to maintain efficient workflow in the plant by leading personnel when the supervisor is not present.
  • Able to “reverse engineer” parts and make a print that will be relied upon for future needs.
  • Charmilles EDM/Program 5 Axis parts utilizing Esprit/AUTO-CAD Software.

Grade 1:

• The tool maker must be able to perform all the tasks in Grades 5 through 2, plus the following:
  • Knowledge of raw materials, production processes, quality control, costs, and other techniques for maximizing the effective manufacture of tooling.
  • Design jigs, fixtures, and templates for use as work aids in the fabrication of parts or products.
  • Works with engineers to promote "smart, easily machined" design work.
  • Ability to and has performed training with welding of all types: Tig, Stick, Gas, Mig, etc.
  • Has obtained a Journeyman’s card.
  • Blueprint interpretation to GD&T standards.
  • Has completed a course in tool design.
  • Has completed a course in tool programming.
  • Competent in all Tool Room machining to close tolerances.
  • Proficient in using AUTO-CAD and Inventor.

NON-ESSENTIAL JOB FUNCTIONS:

• This is not an all-inclusive job description, and there will be times that the position holder will be asked to perform miscellaneous other duties, as assigned, but not essential to this particular job.
• Maintains safe and orderly working conditions and performs work in such ways as to not endanger oneself or fellow employees.
• Responsible for cleanup and general housekeeping of the work area.
• Responsible for keeping the supervisor informed of work-related problems and the progress of work assignments, and accurate labor reporting.