Fabricator

Summary

Sets up and operates CNC press brakes to bend and form sheet metal and plate parts to blueprint and work order specifications. Plans bend sequences, selects and installs punches and dies, runs programmed jobs, monitors machine performance, and inspects parts to ensure they meet quality standards, while maintaining a safe and organized work area.

Essential Duties and Responsibilities

Essential duties and responsibilities include the following. Other duties may be assigned.

Safety

1. Wears required personal protective equipment, keeps hands clear of the point of operation, and verifies that light curtains and other machine guarding are functioning before operating the press brake.

2. Follows lockout/tagout procedures when changing tooling, clearing jams, or performing maintenance, and reports unsafe conditions, near misses, and equipment hazards to the supervisor immediately.

Blueprint and Work Order Interpretation

3. Interprets drawings, program sheets, and work orders to determine work to be done, bend sequences, bend angles, flange dimensions, and dimensions of the finished work piece.

4. Discusses forming and flat-pattern problems with the Fabrication Programmer to improve part fit and quality.

Machine Setup

5. Retrieves preprogrammed machine instructions from the CNC control or network database and verifies the correct program and revision for the job.

6. Selects, positions, installs, and aligns punches, dies, and backgauge fingers in the machine or machine tool holders.

7. Loads material and/or parts manually or with a crane onto the machine, and aligns, positions, and secures material according to setup instructions.

8. Manipulates controls and enters commands to index the machine to the specified set point and start the machine.

Machine Operation and Monitoring

9. Performs a variety of forming and bending operations to close and interrelated tolerances.

10. Depresses the foot pedal or operates hand controls to activate the ram that forms the metal.

11. Observes and listens to machine operation to detect malfunctions, such as worn or damaged punches and dies.

12. Changes punches and dies as specified in setup instructions or when wear or damage is detected.

13. Uses override controls to correct conditions that are out of tolerance or operating unusually.

14. Adjusts ram depth, backgauge positions, and tooling to produce parts to specification when automatic programming is faulty, material varies, or the machine malfunctions.

Quality and Inspection

15. Performs first-piece and in-process inspections to ensure adherence to quality standards and specifications.

16. Measures work pieces, including bend angles and flange lengths, for conformance to specifications.

17. Removes slag and burrs from the edges of work pieces as needed before forming.

18. Notifies the supervisor of discrepancies and segregates nonconforming parts.

Maintenance and Housekeeping

19. Cleans the machine, tooling, and work area, and returns punches and dies to proper storage.

20. Performs routine machine maintenance and reports equipment issues that require repair.

Cross-Functional Support

21. Performs the duties of a General Machine Operator as production needs require.

22. Operates forklift and overhead crane as needed to move material and maintains current forklift training certification.

23. All other duties as assigned.

Supervisory Responsibilities

This job has no supervisory responsibilities.

Growth Opportunity

KMW is committed to developing talent from within. A Numeric Controlled Machine Operator who consistently meets safety, quality, and productivity standards will be encouraged to cross-train on both brake press models (Accurpress and LVD) and on other CNC fabrication equipment, such as the plasma punch and laser, to become a versatile multi-machine operator. Operators who master complex setups, bend sequencing, and troubleshooting, and who help train new operators, may be considered for advancement to a Lead Operator role. Operators who show an interest in CAD/CAM software, flat patterns, and nesting may also be considered for a Fabrication Programmer role. Employees are encouraged to discuss their development goals with their supervisor and Human Resources.

Core Competencies

1. Safety and Security – Observes safety and security procedures; Determines appropriate action beyond guidelines; Reports potentially unsafe conditions; Uses equipment and materials properly.

2. Quality and Attention to Detail – Demonstrates accuracy and thoroughness; Verifies bend angles and flange dimensions on first pieces and throughout production runs; Looks for ways to improve and promote quality; Monitors own work to ensure quality.

3. Technical Proficiency – Sets up and runs the press brake independently; Plans efficient bend sequences; Selects the correct punch and die combinations for each job; Adjusts for springback and material variation; Consistently produces parts within tolerance.

4. Troubleshooting – Recognizes when the machine looks, sounds, or operates abnormally; Identifies whether the cause is tooling, material, or program related; Corrects the issue or escalates it promptly to the supervisor or Fabrication Programmer.

5. Quantity – Meets productivity standards; Completes work in timely manner; Strives to increase productivity.

6. Cost Consciousness – Conserves materials and tooling; Minimizes scrap and rework; Conserves organizational resources.

7. Procedural Compliance – Follows setup sheets, work instructions, and program revisions exactly; Completes inspection and production records accurately; Supports KMW's ISO 9001/45001 quality and safety management systems.

8. Adaptability – Adapts to frequent job changes and re-setups; Manages competing production priorities; Is willing to cross-train on the plasma punch, laser, and other equipment.

9. Dependability – Follows instructions, responds to management direction; Takes responsibility for own actions; Keeps commitments; Is consistently at work and on time.