JOB SUMMARY:

Completely and independently sets up and operates at the highest levels of complexity, the various Cold/Hot header machines in use by the Company to perform operations such as forming, shaping, cutting, piercing etc. on various sizes and types of metal wire, bar stock etc. to required close tolerances per blueprint or other specifications. Operates other machine tools as necessary to produce tooling required for heading set-up and operation. Troubleshoots or reworks any Cold/Hot header problems concerning production parts.

DESCRIPTION OF ESSENTIAL FUNCTIONS AND RESPONSIBILITIES:

1. Reads and interprets blueprints or other documentation to determine machining required, tolerances held, and plans sequence of operations. Plans sequences of operations per manufacturing documentation or good shop practices when documentation is not available.

2. Completely and independently sets-up and operates all types of Cold/Hot Header machine making required adjustments to diameters, grip lengths, depths, etc. to tolerances of ± .0007. Uses various support tools and equipment such as wrenches, pliers, calipers, micrometers etc. to set-up, maintain and repair machine. Heading machines set-up are single or multiple blow as well as single or multiple die or any combination thereof.

3. Loads wire or bar stock, positions and secures to holding device. Verifies feed position. Selects machine speed, tooling, and other variable tasks and items required based upon most efficient methods to maintain tolerances for material and tooling required.

4. Operates all types of Cold/Hot Headers at highest levels of complexity as required for the completion of the various operations necessary on the workpieces being formed. Maintains visual check of work in progress to assure proper functioning of equipment.

5. Provides necessary counts, processes documentation correctly, and maintains daily production logs using computer software applications or production worksheets. Keeps interim records for material, tooling, rework, etc.

6. Works as an active team member by participating in problem solving, team building, and all other team activities to improve the processes, productivity, quality, etc. of the production operations in a cell. Uses interpersonal skills as well as good written and verbal communications. Assists other department members as required.

   Equipment/Process Responsibilities - Performs duties where property, tools, equipment, or machines may be damaged, or man hours lost through improper daily maintenance and attention to processing. Sets-up and adjusts all types of Cold/Hot machines to highest levels of complexity for the jobs performed. Maintains and effects repairs of machines and tooling.

   Material or Product Responsibilities - Performs duties that require close attention to work and supporting documentation specifications and other requirements. Responsible for accuracy of parts formed. Visually and/or with measuring instruments checks work performed for proper results.

   Responsibility for Work of Others - Accuracy of communication is mandatory to the successful production and qualification of workpieces. Must communicate to appropriate personnel any problems or concerns regarding quality of work received or time flow of work in progress as it affects production schedules. Must be able to train employees of equal or lower classification in Header set-up and operation as well as on methods and procedures used by the Company in the production workflow and tracking. Must be able to assist other Cold and Hot Headerman in learning heading operations using single or multiple blow as well as single or multiple die or any combination thereof.

   Safety Responsibilities - Good housekeeping, knowledge of good machine safety is necessary as well as adherence to Company Safety Rules.

   Initiative and Ingenuity - Requires initiative in solving problems associated with the set-up and operation of all types of Header machines and ingenuity in adapting tooling and shop aids to complete forming operations. Makes suggestions for improving the efficiency of workflow or equipment operation. Takes on or reports for additional work as current tasks are completed. Performs other work-related tasks as deemed necessary by Company needs.

WORK ENVIRONMENT:

Environmental Surroundings - Work is in a machine shop environment where noise, temperature fluctuations, the repetitive nature of the job, etc.

Unavoidable Hazards - Possible hazards related to cuts, bruises, finger and hand injuries, muscle strains and burns. Exposure to moving mechanical parts, metalworking fluids, heating elements and airborne particles. Protective equipment and clothing appropriate to the task at hand are required.

EFFORT:

Physical - Able to lift up to 50 pounds. Requires strength to adjust requisite equipment to set-up specifications. Hand and finger manipulation in turning tools/valves/handles or operating knobs/cranks/buttons etc. as well as using precision measuring instruments. Able to reach, bend and stretch. Able to use tools required for machine set-up which may be fatiguing and require extensive physical exertion for extended periods of time. Most job assignments require continuous standing and/or sitting for periods exceeding 15 minutes at a time.

Mental - Work at times is highly repetitive and monotonous. However during set¬ups work varies and requires use of machine shop theory. Setups or machine repair may require improvisation and ingenuity. Reasoning ability required to interpret complex blueprints and documentation of a highly technical nature. Must be able to draw valid conclusions from a variety of abstract and concrete variables. Required to organize work flow for best efficiency.

Visual - Close attention to detail with moderate eye concentration over long periods of time. Able to read various precision instruments such as micrometers, calipers, gauges, etc. Must be able to visually check workpieces for quality.