Detailed Description of work done including duties or tasks over the following period and how often the duty or task was performed, types of machines, equipment, instruments and material I had used.

(Any number in brackets indicate the number of times this task has been completed over a 30 day period)

Legend:

CAD = Computer Aided Design.

CAM = Computer Aided Manufacture.

CNC = Computer Numerical Control.

DNC = Direct Numerical Control.

MPE = Manufacturing Production Engineer

MTT = Machine Tool Technician.

BT50 = Special Spindle nose tooling.

G01 = Programming code for a straight line movement between two points.

G02 = Programming code for a clockwise movement between two points.

           NB. This may involve a Z movement as well, if it is a 3 axis movement.

G03 = Programming code for a clockwise movement between two points.

           NB. This may involve a Z movement as well, if it is a 3 axis movement.

DTI = Dial Test Indicator.

FPD = Finish Part Drawing.

SD = Stage Drawing.

PURCH = A purchased item, using a requisition for procurement.

PRODN = A Produced item, using a route-card for manufacture.

SUBCON = Subcontract operation, operations which are completed by an outside company, this could be machining/painting/plating/wiring/testing.

SET = A set time for setting up an operation.

TA = Time allowed for an operation.

TPM = Total Preventive Maintenance.

KAN/BAN = Japanese term meaning "sign" or "card"

EDM = Electro Dis-charge Machining.

Introduction

Between 1987 & 1996 I worked as a CNC Machine Tool Technician at Horstman Defence Systems Ltd, Bath, UK, for tasks of this Job Function see Para 1 to 3.8

Between 1996 & 2006 I worked as a Manufacturing Production Engineer at Horstman Defence Systems Ltd, Bath, UK, for tasks of this Job Function see Para 5 to 7.1

1          Details of CNC Machine Tool Technician (MTT)

I had the pleasure of operating a Matsurra Vertical CNC Machine tool, occasionally I also operated a Mitsui-Seiki Horizontal CNC Machine tool.

The Matsurra Vertical CNC Machine tool had a 30 tool carousel, BT50 spindle nose tooling & a large machine tool table, around 1meter (x axis) X 1.5meters (y axis) X 1meter (z axis).

2          Items which you require to set-up & operate the machines are as follows:

2.1        Route-card which states the following:

2.1.1     Next operation requiring machining.

2.1.2     Detailed text stating which features need to be machined.

2.1.3     Stating the CNC Machine DNC tool tape no. which the Manufacturing Production Engineer (MPE) has designated, which has been pre-programmed with CAD/CAM software by the MPE.

2.1.4          Stating the Jig/Fixture No. which the Manufacturing Production Engineer (MPE) has designated, which has been designed with CAD software by the MPE, and manufactured by the Company Tool-Room.

2.1.5          Stating any special gauging required to check the component.

2.1.6          Finish Part Drawing (FPD) of the required part.

2.1.7          Stage drawing (SD) of the required part.

2.2      Machined parts, supplied by the shop-floor foreman, which has been completed up to the last operation as stated on the route-card.

2.3      CNC Machine tool DNC tape no. this item is downloaded into the CNC Machine tool via the DNC computer network. (See Para. 2.1.3 above)

2.4      Jig/Fixture tool, this should be stored in the Shop-floor Tool-room stores. (See Para. 2.1.4 above)

2.5      Special Gauges, these should be stored in the Quality Department’s Gauge stores. (See Para. 2.1.5 above) and they are correctly calibrated, usually the gauges are colour coded with coloured tape, to ensure they are calibrated correctly.

3          Setting of CNC Machine tool.

The following stages must be completed to set-up the CNC Machine tool.

3.1        Set-up cutting tools, using data from the CNC Machine tool DNC program. (5)

Each DNC program is programming code, which tells the CNC Machine tool what movements to make & which tools to load into its tool spindle & what G01, G02, G03 movements to make & speed/feed to operate.

3.2        The 1^st page of DNC program data, called ‘Setting up sheet’ will state the following:

Tool Description, Tool No, Speed & Feed, type of cutting tool manufacture (Sandvik, Iscar, and Stellram).

This data allows the MTT to retrieve the cutting tools from the Tool-stores & assemble the cutting tools.

N.B

The spindle nose tooling used by this machine is called BT50, it also uses a pull stud, which is a special item & needs to be checked that the correct pull stud is assembled into the spindle nose tooling, as other CNC machine tools use different pull studs.

3.3               Spindle Nose tooling Loaded into CNC Machine Tool. (120)

The assembled spindle nose tool, assembled to the data specified by the ‘Setting up sheet’ as Para. 3.2, can now be inserted into the CNC Machine tool carousel.        There are 30 possible tool pockets or positions available.

3.4               The 2^nd page of DNC program data, called ‘Datum Setting up sheet’ will state the following:

Fixture position on CNC Machine tool table & Datum points, possible points are G54, G55, G56, G57, G58, G59.

3.5               Jig/Fixture tooling Loaded onto CNC Machine Tool. (5)

The Designated Jig/Fixture, as stated on the route-card as Para. 2.1.4 & Para. 3.4, can now be loaded onto the CNC Machine tool’s table.

Bolt down using suitable bolts & clock-up using a DTI, each jig/fixture usually has a datum edge, which can be clock-up, thus the datum edge is parallel with the X or Y axis.

3.6               Setting of Datum points (5)

Using data from the Datum Setting up sheet set the datum points, G54 & enter them into the setting page.

This is usually performed by moving the X & Y axis & clock-up the datum point using a DTI & enter in to the setting page.

3.7               Machining of Component (120)

This part is actually the most exciting part of the process as you are about to machine a component, to set each tool the following must be taken into consideration.

3.7.1          Load the 1^st tool, set the Z depth or in our case (H01), this is the offset which the DNC program relates to the 1^st tool or T01.

3.7.2          Ensure that if this tool is used with an offset, that the designated offset is set correctly, this data can be taken off the Para. 3.2 Setting Tool sheet.

N.B.

There are two types of offset which can be programmed by the MPE when he programs the DNC program:

1^st method is: If the cutting tool has a diameter of 30mm then he programs 0mm (zero) into the offset, in our case (D99)

2^nd method is: If the cutting tool has a diameter of 30mm then he programs 15mm into the offset, in our case (D99)

It is worth mentioning that the Older Fanuc controls uses one offset for each tool, (offset only) the newer Fanuc controls uses two offsets for each tool, offset & wear offset, so for example if the tool is 30mm dia, (nb adjustments are made using the wear amount not the offset amount) then:

 D99 = 15mm (offset)  0.0mm (wear)

3.7.3          Ensure that the tool is running true, if you have set a Reamer & it is running out by 0.05mm, then it will cut a larger hole, then it will be out of tolerance.

3.7.4          When cutting the material, it could be Titanium or Aluminium or EN24T material, each cutting tool has recommended data from the tool supplier & the data should correspond with the Feed & Speed in the DNC program. (120)

3.7.5          When machined a segment of the machined part, the part can be measured with a pair of Vernier Calipers or Micro-meters to ensure that the measured size is correct to the FPD.

3.7.6          If the part is measured as Para. 3.7.5 and the part is incorrect, there are a few possibilities:

3.7.6.1    The DNC program is incorrect.

3.7.6.2    The cutting tool has been re-ground, so the diameter is 29.9mm instead of 30mm, thus the wear offset in Para. 3.7.2 can be adjusted from 0.0mm to 0.05mm.

3.7.6.3    The cutting tool could be worn, thus it is cutting to small.

3.7.6.4    The cutting tool could be running out, thus it is cutting to big.

3.8               Inspection of Finish machined part.

After the part has been completely machined, then the MTT checks the following & issues part for 1^st off Inspection (15) :

3.8.1          All the features stated on the route-card have been completed.

3.8.2          All gauges are correct to data on FPD & route-card, they are correctly calibrated, and they have the correct colour coded tape on them see Para.  2.5

3.8.3          The FPD & Route-card has the correct drawing issue on them.

5          Details of Manufacturing Production Engineer

I had the pleasure of being promoted from a CNC Machine Tool Technician to a Manufacturing Production working on many projects over the last 10 years, ranging from manufacture, modification and repair of vehicle suspension components, gearboxes, actuators, high pressure-high purity gas vessels, auxiliary power generation engines and electromechanical electronic instrumentation including information display and control equipment for primarily defence applications and other industries, with the provision of logistic support and associated spares. Precision machining and assembly of mechanical and electro-mechanical items includes titanium Aluminium & EN24T materials.

This post is a very wide ranging role & can only be described very briefly.

The basic role of a manufacturing Production Engineer is to investigate & initiate methods of manufacture for designed single parts and/or designed assemblies, to a cost effective plan, using MRP & CAD/CAM Software.

For simplicity we shall start with a simple task of investigating a small assembly.

6                     Investigating a small assembly.

The assembly is broken down into smaller assemblies; all assemblies are designated with the following data:

6.1        Items required to structure an assembly onto a MRP system.

6.1.1          Finish part drawing, this is usually supplied as a Solid model & also as a 2D drawing. The MPE can use the solid model to design jigs/fixtures.

6.1.2          Item list detailing each item required in the assembly, this also includes data which the Chief Buyer will be able to use in conjunction with the FPD to purchase PURCH items.

6.2               The MPE will decide which items are going to be:

6.2.1          PRODN which means, which items are going to manufactured with a route-card. i.e. Being machined in-house.

6.2.1.1.1           A route-card will have to be created by the MPE & entered on to the MAX MRP software, this will include the following data. Operation nos. Description of each operation. Which machine is used in sequence to manufacture the finished part. Which operation is created for any SUBCON operations. Times for each operation for: Set & TA per operation. (120)

6.2.2          PURCH which means, which items are going to purchased via the MRP software, by the Chief Buyer.

6.3               Create a BOM using the Item list data.

Using MRP software enter the item list & quantities required for each piece part & any sub-assemblies.

6.4        Create Jigs/Fixtures for each piece part.

Using CAD software, Create and develop jig & tools detailed manufacturing drawings, (3) bills of materials, (15), requisitions (20), and manufacturing process instructions (30). Using ME10 Co –Create CAD software.

6.4               Create CNC programs for each piece part.

Create and develop CNC programs for CNC Machine Tool machines,  (Milling, lathes & Wire cutting EDM), using Mastercam V9 CAD/CAM (16) & Charmilles EDM - CAD/CAM system (3)

6.5               Create Work packs & Stage Drawings for shop-floor use.

Preparation of work packs for handover to the shop floor; create stage drawing using ME10 Co Create CAD system. (8)

6.6               Create Working Instructions for Assembly Operators.

Produce required manufacturing/working instruction documentation, using MS Excel & digital camera. (15)

6.7               Identify process improvements and cost savings.

Identify process improvements and cost savings, using problem solving tools & techniques. (15)

6.8               Overcome everyday problems.

Liaise with sales, engineering, purchasing, quality control, production & supervisory staff, to overcome everyday problems. (120)

Provide a service to the factory to offer help in overcoming manufacturing challenges, using problem-solving techniques. (180)

6.9               Organisational Development.

Liaise and attend meetings with other company functions necessary to perform duties and aid business and organisational development, create meeting notes using MS Word & e-mail using MS Outlook software. (35)

7.0               Quality requirements.

Understand the requirements of BS5750 ISO9000 quality system and the effect on manufacturing solutions. (15)

7.1        Other duties.

7.1               Create & develop TPM & KAN-BAN Procedure Systems. (1)

7.2               DNC System Administrator, using Seiki-Systems DNC Software, (1).

7.3               Continuous Improvement Team Member, create meeting notes using MS Word & e-mail using MS Outlook software. (4)

7.4                 IT Assistant to IT Director, to help in day-to-day problem solving, connecting printers, re-setting passwords & installing new software. (12)