ABM Set Up 1st Shift
Greenville, AL 36037 US
ABM Set Up - 1st Shift
Schedule for Training 6 am to 4 pm Monday - Thur and 6 am to 2 pm on Friday
Core Competency Requirements
Individual will perform machine setup and operate machines as needed. Machine parts per print for customer orders at various workstations throughout the ABM Department. Complies with current ISO requirements, all safety requirements, and good housekeeping.
Mechanically inclined –Individual needs to be good with tools and machinery and can adapt quickly to fixing things both familiar and unfamiliar.
Mathematical Skills- Ability to perform standard mathematical concepts to effectively make machine adjustments. Ability to apply concepts such as fractions, percentages, ratios, and proportions to practical situations.
Reasoning Ability - Ability to define problems, collect data, establish facts, and draw valid conclusions.
Computer Skills - To perform this job successfully, an individual should have Other Skills and Abilities - Must be detail oriented. Must be organized and have the ability and drive to meet deadlines and work under pressure.
Must be able to perform each duty satisfactorily and meet the physical demands to successfully perform the essential function of this job. The requirements listed below are representative of the knowledge, skill, and/or physical ability required. At CMC’s discretion, exceptions to these can be made to accommodate individual circumstances.
Education and/or experience – High school diploma or GED preferred. Employee must be able to perform basic reading, writing and mathematical functions.
Language Skills – Ability to read and write. Ability to read and comprehend instructions, memorandums and correspondence. Ability to communicate effectively with others both orally and in writing.
Mathematical Skills – Basic mathematical skills are required. Ability to add, subtract, multiply and divide.
Reasoning Ability – Ability to understand and carry out detailed written and oral instructions.
Certificates, Licenses, Registration – Forklift.
Physical Requirements – The physical demands described are representative of those that must be met to successfully perform the essential functions of this job.
While performing the duties of this job, the employee is regularly required to stand, sit, use hands to finger, handle or feel objects, tools, or controls, and reach with hands and arms. Specific vision abilities include close vision, color, distance, peripheral and ability to adjust focus.
Roles & Responsibilities: Training:
15. Successfully complete:
15.1 Safety Training
15.2 Quality Training
15.3 ISO Training
16. Explain the operation the trainee will be learning and how it fits into the entire picture and process.
17. Explain the routing of the product before this task and afterwards.
18. Introduce the trainee to the area setup person, inspector and nearby employees who may be able to provide assistance when needed.
19. Machines must be kept as clean as possible to prevent injuries, machine damage and defects in the quality of the product. Explain the clean-up procedure for the end of the shift and the shop order.
20. Keep hands away from moving machinery parts.
21. Protective guards must be kept in place while the machinery is running.
22. When a problem arises, press the “STOP”button immediately and contact the set-up person or supervisor.
23. Do not tamper with electrical controls, switch boxes and air valves. Contact Maintenance if a problem arises in these units.
24. When loading machinery, make sure parts are properly secured in the fixture before starting the machinery.
25. Lock-Out mechanisms are required on machinery before servicing or maintenance is to begin. Trainees are to be instructed of what a Lockout/Tag out is, and what their responsibilities are when these conditions exist.
26. Watch out for damage contamination or deterioration of all products.
27. Show and explain the pertinent information on the shop order and part drawing such as order number, order requirements, work centers, quantity, and other requirements. Express the importance of following the directions detailed on all documents and making sure all rev levels are the same.
28. Show and explain the importance of properly documenting information on tracking tickets, inspection charts, move tags, first/last piece inspections, caliper checks, etc.
29. Express the importance of stopping the operation when a question or problem arises. When in doubt, DO NOT CONTINUE, ASK QUESTIONS!
30. Show the trainee what the product looks like before and after the operation so they will understand what the operation is doing to the product.
31. Show the trainee the electrical controls and the proper use of each.
32. Demonstrate the emergency stop procedure including any electrical, hydraulic, air or coolant control units.
33. Show the trainee any documented instructions and express the importance of learning these directions during the training period.
34. Check the raw material, in-process and finished product at the work center for proper identification.
35. Show the trainee where nonconforming (scrap) material or parts are to be disposed and express the importance of disposing of the item immediately.
36. Express the importance of properly handling the material or parts to prevent damage and injury.
37. Explain and demonstrate the steps for starting up the machine.
38. Explain and demonstrate how to properly position a part in each vise and locking it in place
39. Make sure an empty clean container is in place completed product.
40. Demonstrate and explain the functions and displays of the computer system. (use instruction manual, if available)
41. Show the trainee the coolant tank and explain the operators’responsibility to check the coolant level and how to fill the tank, when necessary.
42. Explain and demonstrate any secondary operation being performed at the machine;i.E.: sanding, marking, countersinking, filing burrs, etc.
43. Explain and show trainee any past problems and non-conformances with the part being run and what must be done to prevent any recurrences.
44. Show trainee proper handling of unloading parts from drums to the baskets or from baskets to drums in an effort to prevent nicks and burrs.
45. Demonstrate the proper manner to clean chips from the machine to prevent machining problems.
46. Demonstrate the proper way to clean machine and work area at the end of the work shift or shop order.
47. Explain and demonstrate how to remove burrs from finished parts when necessary.
48. Explain and demonstrate how to complete inventory tracking tickets, move tags, shop order logs, and daily time tickets.
49. Explain and demonstrate the proper method of unloading a container of completed product and explain how a drum of completed products gets moved from the area.
50. Explain how to get a finished piece-count at the end of the work shift or shop order, then where the information is recorded.
51. Since each part is different than the previous one, additional training may be necessary after each set-up. Instruct the trainee to contact the trainer when in doubt after each setup.
52. Show the trainee the job description and all the associated operating procedures, and then allow the trainee to read them. Make sure the trainee fully understands these documents before proceeding.
53. Emphasize the importance of producing a quality product, the need for continual inspections and making it right the first time.
54. Explain the current ISO Quality Registration and why it is important that each employee follow procedures fill the necessary forms to produce a Quality Product!
55. Show and explain the part print that accompanies the shop order as well the specifications which must be met at this operation.
56. Show and explain the inspection chart as well as how to document the findings of their inspections. (first/last piece inspection, constant inspection and calibration checks)
57. Explain the “Constant”gaging frequency and the frequency at which an inspection must be recorded. Constantly check all dimension and record every two hours.
58. Demonstrate the proper way to use the measuring equipment and how to inspect the different characteristics being formed.
59. Show and explain the use of the comparative sample and the yellow sample tray.
60. Please refer to FE 127RA, on how to load ABMs.
61. Review process maps for applicable procedures (CMCA 03, 13, 15, 18, 21, 23, 24)
Supervisors are responsible to instruct ABM set-up and ABM operators to take the following steps before making a tool change on ABMS. See below:
62. Turn off tool change switch provided on the ABM operators panel using a key.
63. Remove key from the switch and “Tag Out”the machine. (“Tag Out”form will be provided at the machine)
64. Depress on/off key pad on the ABM control panel to ensure machine is completely locked out of power.
65. Make the tool change.
66. Remove “Tag Out”and turn on the machine using the tool switch. (leave key in the tool switch)