Consider the parts of a toaster, such as the metal or plastic housing or the lever that lowers the toast. These parts, and many other metal and plastic products, are produced by machines that are controlled by machine setters, operators, and tenders—metal and plastic. In fact, machine operators in the metalworking and plastics industries play a major role in producing most of the consumer products on which we rely daily.
In general, these workers can be separated into two groups—those who set up machines for operation and those who operate the machines during production. Machine setters, or setup workers, prepare the machines prior to production, perform initial test runs producing a part, and may adjust and make minor repairs to the machinery during its operation. Machine operators and tenders primarily monitor the machinery during its operation; sometimes they load or unload the machine or make minor adjustments to the controls. Many workers both set up and operate equipment.
Setup workers prepare machines for production runs. Most machines can make a variety of products, and these different items are made by using different inputs or tooling. For instance, a single machine may use different sized tools to produce both large and small wheels for cars. The tools inside the machine must be changed and maintained by setup workers. On some machines, tools may become dull after extended use and must be sharpened. It is common for a setter to remove the tool, use a grinder or file to sharpen the tool, and place the tool back in the machine. New tools are produced by tool and die makers. After installing the tools into a machine, setup workers often produce the initial batch of goods, inspect the products, and turn the machine over to an operator.
Machine operators and tenders are responsible for running machines in manufacturing plants. After a setter prepares a machine for production, an operator observes the machine and the objects it produces. Operators may have to load the machine with materials for production or adjust machine speeds during production. Operators must periodically inspect the parts a machine produces by comparing the parts to blueprint using rulers, micrometers, and other specialized measuring devices. If the products do not meet design parameters, the machine is shut down; if it is a common, minor error the operator may fix the machine, but if it is more serious an industrial machinery mechanic is called to make a repair. Some machines don't require constant input or attention, so the operator may oversee multiple machines at a given time. In many cases, operators must document production numbers in a notebook or computer database at the end of every hour or shift.
Setters, operators, and tenders usually are identified by the type of machine with which they work. Some examples of specific titles are drilling-machine and boring-machine setup workers, milling-machine and planing-machine tenders, and lathe-machine and turning-machine tool operators. Job duties usually vary with the size of the firm and the type of machine being operated. Although some workers specialize in one or two types of machinery, many are trained to set up or operate a variety of machines. Increasing automation allows machine setters to operate multiple machines simultaneously. In addition, newer production techniques, such as team-oriented "lean" manufacturing, require machine operators to rotate between different machines. Rotating assignments results in more varied work, but also requires workers to have a wider range of skills.
Most machine setters, operators, and tenders—metal and plastic work in areas that are clean, well lit, and well ventilated. Nevertheless, stamina is required, because machine operators and setters are on their feet much of the day and may do moderately heavy lifting. Also, these workers operate powerful, high-speed machines that can be dangerous if strict safety rules are not observed. Most operators wear protective equipment, such as safety glasses, earplugs, and steel-toed boots, to protect against flying particles of metal or plastic, noise from the machines, and heavy objects that could be dropped. Many modern machines are enclosed, minimizing the exposure of workers to noise, dust, and lubricants used during machining. Other required safety equipment varies by work setting and machine. For example, those in the plastics industry who work near materials that emit dangerous fumes or dust must wear respirators.
Overtime is common during periods of increased production for most machine setters, operators, and tenders—metal and plastic, but they usually work a 40-hour week. Because many metalworking and plastics working shops operate more than one shift daily, some operators work nights and weekends.
| 1. | Read production schedules and work orders to determine processing sequences, furnace temperatures, and heat cycle requirements for objects to be heat-treated. |
| 2. | Record times that parts are removed from furnaces to document that objects have attained specified temperatures for specified times. |
| 3. | Set up and operate or tend machines, such as furnaces, baths, flame-hardening machines, and electronic induction machines, that harden, anneal, and heat-treat metal. |
| 4. | Determine types and temperatures of baths and quenching media needed to attain specified part hardness, toughness, and ductility, using heat-treating charts and knowledge of methods, equipment, and metals. |
| 5. | Remove parts from furnaces after specified times, and air dry or cool parts in water, oil brine, or other baths. |
| 6. | Position stock in furnaces, using tongs, chain hoists, or pry bars. |
| 7. | Instruct new workers in machine operation. |
| 8. | Adjust controls to maintain temperatures and heating times, using thermal instruments and charts, dials and gauges of furnaces, and color of stock in furnaces to make setting determinations. |
| 9. | Determine flame temperatures, current frequencies, heating cycles, and induction heating coils needed, based on degree of hardness required and properties of stock to be treated. |
| 10. | Load parts into containers and place containers on conveyors to be inserted into furnaces, or insert parts into furnaces. |
| 11. | Mount workpieces in fixtures, on arbors, or between centers of machines. |
| 12. | Set up and operate die-quenching machines to prevent parts from warping. |
| 13. | Move controls to light gas burners and to adjust gas and water flow and flame temperature. |
| 14. | Reduce heat when processing is complete in order to allow parts to cool in furnaces or machinery. |
| 15. | Signal forklift operators to deposit or extract containers of parts into and from furnaces and quenching rinse tanks. |
| 16. | Test parts for hardness, using hardness testing equipment, or by examining and feeling samples. |
| 17. | Position plastic sheets and molds in plastic bags, heat material under lamps, and force confrontation of sheets to molds by vacuum pressure. |
| 18. | Examine parts to ensure metal shades and colors conform to specifications, utilizing knowledge of metal heat-treating. |
| 19. | Cover parts with charcoal before inserting them in furnaces, in order to prevent discoloration caused by rapid heating. |
| 20. | Repair, replace, and maintain furnace equipment as needed, using hand tools. |
| 21. | Start conveyors and open furnace doors to load stock, or signal crane operators to uncover soaking pits and lower ingots into them. |
| 22. | Heat billets, bars, plates, rods, and other stock to specified temperatures preparatory to forging, rolling, or processing, using oil, gas, or electrical furnaces. |
| 23. | Clean oxides and scales from parts or fittings, using steam sprays or chemical and water baths. |
| 24. | Place completed workpieces on conveyors, using cold rods, tongs, or chain hoists, or signal crane operators to transport them to subsequent stations. |
| 25. | Stamp heat-treatment identification marks on parts, using hammers and punches. |
| 26. | Set and adjust speeds of reels and conveyors for prescribed time cycles in order to pass parts through continuous furnaces. |
| 27. | Mount fixtures and industrial coils on machines, using hand tools. |
| 28. | Attach wire or metal to winding mechanisms that will pull parts through furnaces. |
| 29. | Place parts on carts, connect vacuum lines to vacuum tubes, and smooth bags around parts to ensure vacuum. |
| 30. | Position parts in plastic bags, and seal bags with irons. |
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