Rolling Machine Setters, Operators, and Tenders, Metal and Plastic

Overview Nature of Work Knowledge Areas Skills Utilized Job Activities Abilities Job Conditions Work Satisfaction Education/Training

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.

Work environment. 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.	Adjust and correct machine set-ups to reduce thicknesses, reshape products, and eliminate product defects.
2.	Monitor machine cycles and mill operation to detect jamming and to ensure that products conform to specifications.
3.	Examine, inspect, and measure raw materials and finished products to verify conformance to specifications.
4.	Read rolling orders, blueprints, and mill schedules to determine setup specifications, work sequences, product dimensions, and installation procedures.
5.	Manipulate controls and observe dial indicators in order to monitor, adjust, and regulate speeds of machine mechanisms.
6.	Start operation of rolling and milling machines to flatten, temper, form, and reduce sheet metal sections and to produce steel strips.
7.	Set distance points between rolls, guides, meters, and stops, according to specifications.
8.	Thread or feed sheets or rods through rolling mechanisms, or start and control mechanisms that automatically feed steel into rollers.
9.	Position, align, and secure arbors, spindles, coils, mandrels, dies, and slitting knives.
10.	Direct and train other workers to change rolls, operate mill equipment, remove coils and cobbles, and band and load material.
11.	Fill oil cups, adjust valves, and observe gauges to control flow of metal coolants and lubricants onto workpieces.
12.	Record mill production on schedule sheets.
13.	Install equipment such as guides, guards, gears, cooling equipment, and rolls, using hand tools.
14.	Signal and assist other workers to remove and position equipment, fill hoppers, and feed materials into machines.
15.	Calculate draft space and roll speed for each mill stand in order to plan rolling sequences and specified dimensions and tempers.
16.	Select rolls, dies, roll stands, and chucks from data charts in order to form specified contours and to fabricate products.
17.	Activate shears and grinders to trim workpieces.
18.	Remove scratches and polish roll surfaces, using polishing stones and electric buffers.
19.	Disassemble sizing mills removed from rolling lines, and sort and store parts.

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