Tool and Die Maker

PURPOSE:

At the highest level of complexity, analyzes specifications, lays out metal stock, sets up and operates machine tools, and fits and assembles parts to fabricate and repair metalworking dies, cutting tools, jigs and fixtures, gauges, and machinists&39; hand tools by performing the following duties.

ESSENTIAL JOB FUNCTIONS:

• Demonstrate the ability to organize, instruct, and supervise large tooling programs.
• Verify dimensions, alignments, and clearances of finished parts for conformance to specifications, using measuring instruments such as calipers, gauge blocks, micrometers, and dial indicators.
• Measure dimensions of completed products or work pieces to verify conformance to specifications.
• Study blueprints, sketches, models, or specifications to plan sequences of operations for fabricating tools, dies, or assemblies.
• Review blueprints or other instructions to determine operational methods or sequences.
• Set up and operate conventional or computer numerically controlled machine tools such as lathes, CNC machines, milling machines, and grinders to cut, bore, grind, or otherwise shape parts to prescribed dimensions and finishes.
• Operate grinding equipment.
• Visualize and compute dimensions, sizes, shapes, and tolerances of assemblies, based on specifications.
• Calculate dimensions of workpieces, products, or equipment.
• Inspect finished dies for smoothness, contour conformity, and defects.
• Fit and assemble parts to make, repair, or modify dies, jigs, gauges, and tools, using machine tools and hand tools.
• Assemble machine tools, parts, or fixtures.
• Conduct test runs with completed tools or dies to ensure that parts meet specifications, making adjustments as necessary.
• Conduct test runs of production equipment.
• File, grind, shim, and adjust different parts to properly fit them together.
• Smooth metal surfaces or edges.
• Operate grinding equipment.
• Select metals to be used from a range of metals and alloys, based on properties such as hardness and heat tolerance.
• Select production input materials.
• Lift, position, and secure machined parts on surface plates or worktables, using hoists, vises, v-blocks, or angle plates.
• Mount materials or workpieces onto production equipment.
• Smooth and polish flat and contoured surfaces of parts or tools, using scrapers, abrasive stones, files, emery cloths, or power grinders.
• Polish materials, workpieces, or finished products.
• Smooth metal surfaces or edges.
• Develop and design new tools and dies, using computer-aided design software.
• Design tools, fixtures, or other devices for production equipment.
• Design jigs, fixtures, and templates for use as work aids in the fabrication of parts or products.
• Design tools, fixtures, or other devices for production equipment.
• Measure, mark, and scribe metal or plastic stock to lay out machining, using instruments such as protractors, micrometers, scribes, and rulers.
• Measure materials to mark reference points, cutting lines, or other indicators.
• Set up and operate drill presses to drill and tap holes in parts for assembly.
• Drill holes in parts, equipment, or materials.
• Feed materials or products into or through equipment.
• Cut, shape, and trim blanks or blocks to specified lengths or shapes, using power saws, power shears, rules, and hand tools.
• Shape metal workpieces with hammers or other small hand tools.
• Cut industrial materials in preparation fabrication or processing.
• Possess working knowledge of CAD/CAM programs.
• Able to train toolmakers of lesser skill
• Evaluate quotes to determine cost justification and manufacturing feasibility.
• Ability and knowledge to solve tooling design, rework, and wax press operation problems
• Perform cost analysis for rework/repair and to select the most efficient and cost effective solution to the problem.
• Understanding of tooling automation methods and practices.

SPECIAL SKILLS AND PHYSICAL REQUIREMENTS:

• Trade school experience in machine trades or a minimum of one year experience as machinist performing close tolerance machining.
• Ability to read blueprints.
• Understand dimensioning and tolerances
• Must maintain an average production rate at standard, or average, with an acceptable rework rate and scrap rate for the previous 6 months period.
• Must show the ability to take necessary steps to anticipate problems, or prevent any reoccurrence, of production problems, and must communicate and consult with lead or supervisory personnel. Any suggested changes must be signed off by the supervisor before implementing change.
• Must display a willingness to learn on-the-job and take vocational or educational courses when offered.

REPORTING RELATIONSHIPS:

• Reports to the Engineering Manager.

EDUCATION AND EXPERIENCE:

• Requires one to three years experience, or a combination of work experience and trade school.
• Educational background should include college algebra or geometry or demonstrate the ability to build and design simple gauges and fixtures as well as to repair and rework all tooling.