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 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. 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. 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. Because the setup process requires an understanding of the entire production process, setters usually have more training and are more highly skilled than those who simply operate or tend machinery. As new automation simplifies the setup process, however, less skilled workers also are increasingly able to set up machines for operation.
Setters, operators, and tenders usually are identified by the type of machine with which they work. Some examples of specific titles are drilling- and boring-machine toolsetters, milling- and planing-machine tenders, and lathe- 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.
Machine setters, operators, and tenders—metal set up and tend machines that cut and form all types of metal parts. Setup workers plan and set up the sequence of operations according to blueprints, layouts, or other instructions. Often this involves loading a computer program with instructions into the machine's computer controls. On all machines, including those with computer controls, setup workers respond to problems during operation by adjusting the speed, feed and other variables. They also choose the proper coolants and lubricants and select the instruments or tools for each operation. Using micrometers, gauges, and other precision measuring instruments, setup workers compare the completed work within the required tolerances.
Although there are many different types of metalworking machine tools that require specific knowledge and skills, most operators perform similar tasks. Whether tending grinding machines that remove excess material from the surface of solid piece of metal or presses that extrude molten metal through a die to form wire, operators usually perform simple, repetitive operations that can be learned quickly. Typically, these workers place metal stock in a machine on which the operating specifications have already been set. They watch one or more machines and make adjustments to the machines based on either reading from computers and gauges or measuring the resulting product. Regardless of the type of machine they operate, machine operators usually depend on more skilled and experienced setup workers for major adjustments when the machines are not functioning properly.
Machine setters, operators, and tenders—plastic set up and tend machines that transform plastic compounds—chemical-based products that can be produced in powder, pellet, or syrup form—into a wide variety of consumer goods such as toys, tubing, and auto parts. These products are manufactured by various methods, of which injection molding is the most common. The injection-molding machine heats and liquefies a plastic compound and forces it into a mold. After the part has cooled and hardened, the mold opens and the part is released. Many common kitchen products are produced with this method. To produce long parts, such as pipes or window frames, an extruding machine usually is used. These machines force a plastic compound through a die that contains an opening with the desired shape of the final product. Blow molding is another common plasticsworking technique. Blow-molding machines force hot air into a mold that contains a plastic tube. As the air moves into the mold, the tube is inflated to the shape of the mold, and a plastic container is formed. The familiar 2-liter soft-drink bottles are produced by this method.
Work environment. Most machine setters, operators, and tenders—metal and plastic work in areas that are clean, well lit, and well ventilated. Nevertheless, many operators require stamina, because they 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 and earplugs, to protect against flying particles of metal or plastic and against noise from the machines. However, 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 face masks or self-contained breathing apparatus.
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. | Observe continuous operation of automatic machines to ensure that products meet specifications and to detect jams or malfunctions, making adjustments as necessary. |
| 2. | Measure and visually inspect products for surface and dimension defects in order to ensure conformance to specifications, using precision measuring instruments. |
| 3. | Set up, operate, or tend metal or plastic molding, casting, or coremaking machines to mold or cast metal or thermoplastic parts or products. |
| 4. | Position and secure workpieces on machines, and start feeding mechanisms. |
| 5. | Turn valves and dials of machines to regulate pressure, temperature, and speed and feed rates, and to set cycle times. |
| 6. | Remove finished or cured products from dies or molds, using hand tools, air hoses and other equipment; stamp identifying information on products when necessary. |
| 7. | Skim or pour dross, slag, or impurities from molten metal, using ladles, rakes, hoes, spatulas, or spoons. |
| 8. | Trim excess material from parts, using knives, and grind scrap plastic into powder for reuse. |
| 9. | Cool products after processing to prevent distortion. |
| 10. | Install dies onto machines or presses, then coat dies with parting agents, according to work order specifications. |
| 11. | Mix and measure compounds, or weigh premixed compounds; then dump them into machine tubs, cavities, or molds. |
| 12. | Observe meters and gauges to verify and record temperatures, pressures, and press-cycle times. |
| 13. | Spray, smoke, or coat molds with compounds to lubricate or insulate molds, using acetylene torches or sprayers. |
| 14. | Read specifications, blueprints, and work orders to determine setups, temperatures, and time settings required to mold, form, or cast plastic materials, as well as to plan production sequences. |
| 15. | Adjust equipment and workpiece holding fixtures, such as mold frames, tubs, and cutting tables, to ensure proper functioning. |
| 16. | Remove parts such as dies from machines after production runs are finished. |
| 17. | Inventory and record quantities of materials and finished products; requisition additional supplies as necessary. |
| 18. | Pour or load metal or sand into melting pots, furnaces, molds, or hoppers, using shovels, ladles, or machines. |
| 19. | Unload finished products from conveyor belts, pack them in containers, and place containers in warehouses. |
| 20. | Connect water hoses to cooling systems of dies, using hand tools. |
| 21. | Preheat tools, dies, plastic materials, or patterns, using blowtorches or other equipment. |
| 22. | Operate hoists to position dies or patterns on foundry floors. |
| 23. | Smooth and clean inner surfaces of molds, using brushes, scrapers, air hoses, or grinding wheels, and fill imperfections with refractory material. |
| 24. | Obtain and move specified patterns to work stations, manually or using hoists, and secure patterns to machines, using wrenches. |
| 25. | Perform maintenance work such as cleaning and oiling machines. |
| 26. | Repair or replace damaged molds, pipes, belts, chains, or other equipment, using hand tools, hand-powered presses, or jib cranes. |
| 27. | Maintain inventories of materials. |
| 28. | Select coolants and lubricants, and start their flow. |
| 29. | Assemble shell halves, patterns, and foundry flasks, and reinforce core boxes, using glue, clamps, wire, bolts, rams, or machines. |
| 30. | Pull level and toggle latches to fill molds, to regulate tension on sheeting, and to release mold covers. |
| 31. | Select and install blades, tools, or other attachments for each operation. |
| 32. | Shape molds to specified contours, using sand, and trowels and related tools. |
| 33. | Clamp metal and plywood strips around dies or patterns to form molds. |
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