Safety - Safety Procedures
Demonstrate ability to safely enter a work cell including performing proper Energy Control Power Lockout (ECPL) procedures.
Describe how an ECPL Control Gravity procedure as it relates to robotic manipulator prior to performing any inspection or maintenance work.
Describe the proper PPE (Personal Protective Equipment) that should be worn while operating a CNC machine as well as other OSHA safety precautions and practices you should take in regards to material handling, lifting, chemicals, inhalation, etc.
Describe the proper personal grooming and work clothes worn while operating machinery and the safety requirements including lengths, jewelry, hair, shoes, gloves, protective sleeves, etc.
Describe the Emergency Stop Activation procedure and when it should be used. Then describe the Emergency Stop Reset procedure to recover.
Describe the possible hazardous areas inside and outside of a CNC machine area including pinch points, sharp edges, confined space, etc., as well as locating guarding and other safety features which must be in place and operational before starting the machine.
Describe the safety checks to perform before starting a CNC operation or maintenance.
Describe the functions of the Set-up /Run mode switch if so equipped, and the safety hazards involved.
Demonstrate knowledge of Arc Flash, locating and reading arc flash labels, and properly interpreting hazard level and PPE (Personal Protective Equipment) requirements.
Demonstrate knowledge of safety precautions and procedures for working from an elevated position including walkways (catwalks), ladders, platforms, scaffolds, mechanized lifts, etc.
Demonstrate the proper handling, storage, or disposal of materials in the assembly and operation of production equipment according to plant, local, federal regulations and laws as well as EPA, Hazmat, OSHA, and any other applicable organizations or agencies.
Locate and describe the safety features of a machine and related equipment.
Locate the emergency stop pushbutton(s) and explain when and when not to activate its function.
Locate the teach pendant Hold-to-Run button(s), a.k.a.: live man switch, and explain its function.
Locate and identify the following safety components as applicable: ECPL signage, all Emergency Stop pushbuttons, gate interlocks, floor markings, area scanners, light curtains, vision sensors, pressure mats, warning/indicator lights.
Identify and demonstrate how to properly use physical safety restraint equipment: wrist restraints, fall protection, etc.
Components - General Knowledge of Machine/Work Cell Components/Concepts
Demonstrate the ability to describe the machine(s) in operation (as applicable) and the functions they perform.
Demonstrate knowledge of a given work cell and the components within and outside. Describe the operational motions involved in terms of direction of travel, rotation, axes, etc.
Demonstrate knowledge of the different types of operations performed at a given workcell such as; Manual, Semi-automatic, Automatic.
Demonstrate knowledge of the production line, where key features regarding safety (PPE distribution, eye wash and/or emergency shower stations, emergency contacts, etc.), operations (control panels, electrical panels), services (pneumatic, hydraulic, coolant panels, etc.) are located.
Describe the related ancillary equipment and their functions i.e., Feeders, Conveyors, Fixtures, as well as specific equipment such as; Dispensing units, Lubricators, Gauging, Testing,, Visual checking, etc.
Describe the following production line areas; Zones, Buffers, Repair bays, Bypasses, Rollovers, etc., as applicable.
Describe the concepts of FIFO (First In, First Out) and JIT (Just In Time) inventory management.
Demonstrate the ability to describe a robotic cell and the components, Manipulator, Controller, Teach pendant, EOAT (End of Arm Tooling), Fixtures, etc.
Locate and describe the following services; Electrical, Pneumatic, Hydraulic, Coolant, Water, Lubrication, Waste product removal, Venting systems, etc., in detail.
Demonstrate ability to trace services hierarchy from origin to end use (upstream to downstream) and identify individual components.
Describe the loading systems used, gantry load, lift assist, robotic, as well as automatic vs. manual.
Describe control systems such as Run bars, Palm buttons, Foot pedals used to actuate operations.
Describe the various tooling used for a given operation, such as metal removal (drills, cutters, etc.), assembly (nutrunners, presses, etc.) , welding, sorting, etc.
Describe the various types of cutting lubricants/coolants used in cutting operations, how to choose the correct one and the benefits of one over another (i.e., MQL - Minimum Quantity Lubrication, synthetic oils, natural oils, hybrid oils, additives, etc.).
Describe the facilities for storing raw/production parts (dunnage, bins, racks, etc.) and the mechanisms for replenishing/distribution (order buttons, signal stacklights, other).
Planning/Setup - Math Skills
Demonstrate converting fractions to decimal, and decimal to fractions.
Demonstrate converting U.S. standard (Imperial) to metric, and metric to U.S. standard (Imperial).
Describe various geometric principles/formulas relating to triangles, quadrilaterals, and circles that are applied to obtain needed data for setting up projects and calculating tool locations.
Demonstrate ability to calculate feeds and speeds using SFPM (Surface Feet per Minute), RPM (Rotations Per Minute), Chip Loads Per Tooth or Inches Per Tooth (IPT), Chip Load Per Tool in Inches Per Revolution (IPR), and the feed rate in IPM (inches per minute).
Demonstrate ability to interpret tool manufacturer provided information to setup tooling parameters.
Planning/Setup - Metrology
Demonstrate the proper selection and use of fractional and decimal scales as it applies to measuring parts to the accuracy of a part print.
Demonstrate the ability to properly use the following precision measuring instruments: I.D. and O.D. Micrometers (Vernier, Dial, and Digital), Height Gage, Vernier and Digital Calipers, Dial, and Digital Indicators with Magnetic Stand, Bore Gauges, Depth Gauges, Digital Protractors.
Demonstrate the proper use of Gauge Blocks, Gauge Pins, 1-2-3 & 2-4-6 Blocks, Angle Blocks, Go/No Go Gauges, Feeler Gauges, Precision Levels, Sine Bar & Plate, Thread Gauges, and Surface Plates.
Explain the care, inspection, and calibration techniques for Micrometers, Height Gages, Calipers, Indicators, Depth Gages, Bore Gauges, and Surface Plates.
Describe the uses of a CMM (Coordinate Measuring Machine) and Optical Comparator in a machining or operation environment.
Planning/Setup - Blueprint Reading
Demonstrate the ability to read and interpret a blueprint including the title block, revision block, line types, symbols, dimensions, scale, tolerances, orthographic and isometric views.
Discuss Geometric Dimensioning and Tolerancing (GD&T) in terms of symbols used, tolerancing, modifiers, datums. Feature Control Frames, Datum Features, Maximum Material Condition (MMC) and Least Material Condition (LMC), etc.
Explain how to read and interpret ISO and ANSI surface finish symbols (a.k.a. surface texture or surface roughness symbols).
Demonstrate ability to interpret assembly drawings, cross sections, part identification, BOM (Bill of Materials), assembly notations, part hierarchy (assembly tree if viewing 3D model), etc.
Demonstrate ability to read electrical schematic diagrams and P&ID (Piping and Instrumentation Diagram) sheets.
Planning/Setup - Metallurgy
Demonstrate basic knowledge of material types used in metal forming operations and the characteristics they process for determining tool selection, feeds and speeds, tool wear, etc.
Describe the various material hardness scales (Rockwell, Brinell, Vickers) and how they influence tool selection to achieve best results.
Describe surface finish characteristics, ways to measure, (Ra vs. RMS) and machine process choices to achieve the specified finish.
Demonstrate proper use of machine cutting tools for preforming material stock for a semi-finish work.
Demonstrate the proper handling of hand tools and how to use them safely to perform manual operations such as honing, tapping, shaping, deburring, etc., including but not limited to; electrical, pneumatic, and standard tools such as drills, grinders, saws, presses, hammers, chisels, files, punches, pliers, screwdrivers.
Demonstrate ability to fill out and/or read setup sheets. Include information such as the part number, fixture location, tooling list, the X, Y and Z zero points, etc.
Demonstrate job planning and sequencing to effectively and safely produce qualified parts to specifications in a timely manner.
Demonstrate accurately transferring part detail information to part such as hole centers, surface features, etc., using appropriate tools.
Demonstrate setup and installation of workholding fixtures, setting datum points, work offset values (a.k.a. Work Zero Offset), and verify clamping pressures. Include process planning for workpiece turning for multiple operations on different faces and how to maintain squareness, perpendicularity, or parallelism within acceptable TIR (Total Indicator Reading) measurements.
Demonstrate setup and installation of tools including parameters and tool offset values (a.k.a. Touching Off Tools) for an operation. Discuss the different methods commonly used to set tool offset values (jogging, precision block, probes, etc.)
Demonstrate Homing a machine to set reference points.
Demonstrate setting part zero reference points.
Demonstrate setting up a tool changer such as a turret, magazine, or carousel, and inputting tool information to tool management program.
Calculate Feeds and Speeds values for a given CNC operation.
Demonstrate loading programs into CNC memory.
Demonstrate running a warm-up program prior to production.
Demonstrate running a test (air) program without parts prior to production.
Demonstrate running a first run part and checking dimensions to specifications on part print.
Planning/Setup - Production Setup/Scheduling
Explain the sequence of operations (SOO) for a given production operation, including cycle times for each operation and manpower requirements.
Describe the relationship between cycle times/production rates PPH (Parts Per Hour) and PPS (Parts Per Shift) and where this information is typically found.
Demonstrate the ability to set up a production schedule taking into account, but not limited to, the following: raw materials supply, equipment capabilities, operator scheduling, planned maintenance, inventory management, etc.
Demonstrate the ability to determine the proper tooling required, calibration, and setup (mechanical and/or programming) requirements, as well as mechanical/technical support personnel involvement.
Demonstrate the ability to setup an inspection schedule (i.e., number of parts tested per shift) and the qualification parameters to meet production requirements and specifications.
Demonstrate supply chain knowledge and delivery systems to coordinate with other departments to meet fulfillment and timelines (delivery of raw materials, parts, finished part removal, etc.).
Describe the specifics of the production part (material specifications, raw material properties, machine tolerances, environmental issues that could affect production decisions.
Identify production monitoring mechanisms (HMI screens, Andon systems, etc.) as well as personal observation used in the production environment.
Demonstrate ability to setup and monitor inventory tracking, coordinate with Shipping/Receiving as well as other related department, and maintain specified production rates.
Demonstrate ability to identify delays in production and adjust or modify scheduling and production resources (raw materials, assembly parts, quality assurance, etc.) to meet production requirements. Also, develop plans should production delays arise and notification procedures of the appropriate personnel involved.
Demonstrate ability to run production while adhering to timeline and product specifications in a consistent, safe, and quality controlled manner by maintaining equipment as recommended and utilizing the five senses to identify potential problems before they occur.
Demonstrate knowledge of plant personnel to contact and specific procedures to follow should problems occur whether in safety, production, quality, equipment, or any other area outside your expertise.
Demonstrate ability to accurately document production output/modifications to plan, calculate expenditures, and monitor ROI (Return on Investment), and deviations from plan.
Demonstrate ability to properly disassemble and reassemble equipment setup for production changeover.
Demonstrate ability to cross train personnel as well as participate in cross training/skill expansion activities to improve overall production capabilities.
Demonstrate knowledge of identifying and improving if necessary the setup of production equipment taking into account ergonomic and safety requirements as specified by OSHA and plant specific policies.
Planning/Setup - Continuous Improvement
Demonstrate ability to describe the production's performance impact on the business goals and identify continuous improvement opportunities through the use of SWOT (Strength, Weakness, Opportunity, Threats) analysis, Six Sigma, and other performance based resources.
Demonstrates the knowledge of competitor's operations and the global environment, identifies ways to enhance and improve operations in response to the market influence to business plans.
Demonstrates the ability to perform cost analysis based on key performance markers (indicators) for specific operations and focus on targets for decision making.
Demonstrate ability to recognize cost saving efficiencies (i.e., kitting, dunnage travel, lean manufacturing, etc.) and make recommendations to improve and promote best production practices and ROI (Return on Investment).
Demonstrates the communication skills required when performing continuous improvement feedback sessions such as "scrum" meetings with co-workers.
Operation - Operator Control Panel and Screens
Explain the Operator panel screen elements: Menu, status bar, buttons, task bar, message bar, quick select, etc. (varies per screen, manufacturer, mode) of a program and how to navigate between various operating and monitoring screens.
Identify the basic areas of the teach pendant and their functions (as applicable).
Explain the color coded functions of a stacklight for a given system if so equipped.
Identify and describe the functions of the buttons, switches, indicator lights, displays, gages, which might be typically found on an Operator or equipment panel for a given production system.
Demonstrate the pre-checks required before starting a machine or operation.
Demonstrate the machine or operation Start-up sequences in Manual and Automatic modes.
Demonstrate the Shut-down sequence for a short term shut-down (i.e., shift change, tool change).
Demonstrate the Shut-down sequence for a long term shut-down (i.e., maintenance, weekend).
Demonstrate changing from Automatic mode to Manual mode and vice-versa.
Demonstrate operating in Automatic Step (block or single mode) and Continuous modes.
Demonstrate stopping machine in cycle and recovering.
Demonstrate the Access Door opening procedure.
Demonstrate a Tool Change procedure for a manual and automatic (tool changer) operation.
Explain a fault recovery and restart procedure.
Demonstrate ability to perform mill, lathe, and turning machining operations using various tooling setups including between centers, chucks, work support, material feeder, etc.
Demonstrate ability to machine on multiple work planes during an operation including changing part orientation, fixtures, tool setups, while maintaining final specification.
Demonstrate ability to safety extract broken or jammed production part, and/or tooling in the event of an operational or equipment failure.
Demonstrate ability to recover from a major crash, including inspecting for damaged equipment and/or broken tooling, part extraction, resetting the equipment, determining the cause of the event, and notifying appropriate personnel with detailed information.
Demonstrate ability to safety operate, maneuver, navigate driven vehicles or mechanized equipment, such as forklifts, transport vehicles, cranes, etc., as necessary to perform production operations.
Demonstrate ability to document, accurately track and record production operation specifications, modifications, quality inspection results, and production output rates to plan documentation.
Demonstrate manually jogging the machine in all available axis transitionals (linear and rotary if applicable) using the control panel and teach pendant including changing the direction, and jog rate.
Demonstrate the procedure for jogging with the work door in the open position.
Demonstrate varying jog speed (override) while manually jogging an axis.
Operation - Coordinate Systems
Explain the concept of the Cartesian Coordinate System, Work (Workpiece) Coordinate System, Polar Coordinates, Coordinate Planes, and Quadrant Coordinates.
Demonstrate the "Right Hand Rule" in relationship to the available axes.
Explain the concepts of Relative (Incremental) vs. Absolute Coordinates.
Operation - Error/Alarm Messages
Explain how warning and error messages are displayed at the Operator panel and how to access the History screen.
Locate where error messages and warnings are located on the teach pendant and how to view alarm history.
Demonstrate the procedure for fault reset, clearing the alarms, and reset teach pendant if necessary.
Programming - Basic Program Functions
Explain accessing the programming environment and simulation software.
Demonstrate loading production programs to the system controller (from teach pendant if applicable).
Demonstrate the procedure for backing up the production program(s).
Demonstrate the process for switching between programs and changing the program uploaded to the machine.
Demonstrate the procedure for restoring the production program(s) from back up (removable storage or network system).
Explain the three basic operations/essential functions of a CNC machine regarding tool paths.
Explain what the G Code is and it's basic functions. List examples of G Code functions (G codes vary by machine).
Explain the purpose of M Codes and how they correlate to the machine. List examples of M Codes functions (M codes vary by machine).
Explain the functions of the remaining letters of the G Code/CNC program (N, X/Y/Z, F, S, T, I/J, R, A, B, C, D, L, P).
Explain modal G Codes and how they function within groups.
Programming - Editing Programs
Demonstrate editing a CNC program G Codes to adjust tool offsets.
Demonstrate editing a CNC program G Codes to adjust work offsets.
Demonstrate the ability to create a basic CNC program using G Code (as appropriate for available machine), incorporating both linear and circular interpolation. Show how to adjust speed, force, and to run in step, cycle, and continuous modes.
Demonstrate creating a peck drilling tool path program including dwell time.
Explain the uses of "canned" cycles in CNC G Code programming.
Demonstrate adjusting programs based on inspection of parts to shop prints to maintain specifications (such as work piece holding fluctuation, tool wear, etc.).
Demonstrate adjusting programs based on chip formation, cut conditions, tool wear, and cutter rake angle.
Demonstrate adjusting programs/settings for other types of production operations/equipment (i.e., nutrunners, robotics, PLC (Process Logic Control), etc.).
Demonstrate proficiency in using a computer and Microsoft Office programs (Word, Excel, PowerPoint) software to access and develop documentation when necessary such as but not limited to product manuals, training manuals, reports, etc.
Demonstrate proficiency in using CAD (Computer Aided Design) software to access drawings and make minor modifications when necessary.
Quality - Quality Control and Finishing
Describe quality control management systems and practices such as ISO 9001, Six Sigma, and how to utilize statistical information gathering techniques and develop capability studies.
Demonstrate ability to identify machining operations defects, including but not limited to surface finish, dimensions (overall, run-out, etc., metal removal (holes, slots, knurling, routing, burrs, etc.), assembly (accuracy, fit, alignment, etc.).
Describe setting up and utilizing a part inspection plan including sampling rates, data collection, charting or graphing test results, mean deviation, and actionable steps.
Demonstrate measuring workpieces (first run, production) to ensure compliance to shop print specifications.
Demonstrate utilizing work sheets, program notes, etc., to convey production changes for continual improvement.
Describe typical benchwork required for finishing parts including cleaning, deburring, honing, tapping, lapping, polishing, coating, engraving, stamping, etc.
Demonstrate ability to accurately monitor and record quality inspection results, interpret data, identify root cause(s) of failed parts, and take corrective measures to improve production where necessary to lower defect rates.
Demonstrate proper finished part handling and storage.
Demonstrate developing part tracking mechanisms to follow inventory production, inspection, transportation, storage, such as lot numbering/tagging systems, Bar/QR code readers, RFID (Radio Frequency Identification) chips, etc.
Demonstrate knowledge of procedures for the proper identifying, recording, and handling of non-conformance parts, including rework, disposal (recycle or other), and notification of source supplier (internal or external) as well as any other stake holders (co-workers, supervisors, etc.).
Maintenance - Maintenance Safety
Demonstrate how to place the machine into safe maintenance position and locking it out.
Explain SDS (Safety Data Sheet) information, where to locate and how to read them.
Demonstrate knowledge of OSHA safety standards as well as plant or shop specific safety protocols.
Explain choosing proper PPE (Personal Protective Equipment) for the specific maintenance task to be performed.
Explain the proper use of air gun and handling of chips when cleaning the machine.
Describe the practice of contamination control utilized in a "clean room" type production environment and the personal garments required to ensure the safety/quality of the equipment and/or production parts.
Maintenance - Basic Maintenance
Demonstrate the necessary procedures for cleaning and maintaining the machine(s), work area, fixturing, and tools. Include the proper use of approved cleaning solvents, their handling, and storage.
Explain what it means to use the five senses to inspect the machine(s) and related equipment.
List examples of potential mechanical problems to look for during an inspection of the machine and related equipment.
List examples of potential electrical problems to look for during an inspection of the machine and related equipment.
List examples of potential pneumatic problems to look for during an inspection of the machine and related equipment.
List examples of potential hydraulic problems to look for during an inspection of the machine and related equipment.
List examples of potential lubrication problems to look for during an inspection of the machine and related equipment.
Demonstrate how to identify tool wear (inserts, part touching details, actuators, etc.), and tool holder issues.
Describe the principle of 5S (Sort, Set in Order, Shine, Standardize, Sustain) and the benefits to the production operation in following its practices.
Demonstrate ability to maintain a safe work environment to protect workers (including yourself) from harm by maintaining work/traffic areas including: warnings signage, eliminating trip/slip hazards, promote safe working behavior, and following emergency procedures.
Demonstrate the ability to follow a preventive maintenance schedule and properly document via maintenance log books or computer maintenance programs, results, tests, additional actions required (troubleshooting, repairs, etc.).
Demonstrate ability to set up maintenance schedule based on equipment manufacturer recommendations: MTBF (Mean Time Between Failures), life expectancy, wear parts list, spare parts list, etc.
Demonstrate the proper cleaning/sanitizing of "clean room" equipment as well as ventilation systems, (High Efficiency Particulate Air (HEPA) filters, etc., and an understanding of contamination control.
Maintenance - Maintenance Procedures
Demonstrate the proper cleaning/sanitizing of "clean room" equipment as well as ventilation systems, (High Efficiency Particulate Air (HEPA) filters, etc., and an understanding of contamination control.
Demonstrate replacing pneumatic and hydraulic filters used on the machine.
Demonstrate Probe (tool setting and work offset) replacement (as applicable).
Demonstrate drive belt replacement/tensioning procedure.
Demonstrate how to check/adjust spindle drawbar or tool clamping force.
Demonstrate proper waste product storage (i.e., chip bin) removal and replacement procedure.
Demonstrate PLC battery replacement procedure (as applicable).
Demonstrate the procedure for taking a hydraulic system oil sample, doing a visual inspection, and filling out request for oil contamination analysis test.
Demonstrate proper tool/equipment checks, as necessary per O.E.M (Original Equipment Manufacturer) recommendations as well as the ability to operate safely any required testing, gauging, adjusting, diagnosing tools, especially those which may be hazardous in nature (chemical, laser, heat, etc.).
Maintenance - Machine Calibration
Demonstrate how to put the machine into calibration position and the steps required for calibrating the machine per preventive maintenance schedule or suspected mechanical alignment error.
Demonstrate calibrating the work setting probe and tool setting probe.
Demonstrate calibrating sensors used such as surface gage, thermo probes, pressure transducers, etc.
Maintenance - Tooling Maintenance
Demonstrate the procedure for tool sharpening.
Demonstrate tool replacement procedures for a given type, such as: insert, drill, cutter, etc., utilizing heat shrink, hydro collet, standard collet, end mill.
Explain the inspection of various tool holders for symptoms such as pull stud condition, taper fretting, chattering, etc.
Describe the procedure(s) required for maintaining and storage of hand tools (manual and automatic) which may be used in a given production operation.
Troubleshooting - Safety Considerations
Demonstrate how to determine the proper PPE (Personal Protective Equipment) required for troubleshooting live equipment.
Explain the considerations to ensure the safety of personnel and equipment when performing troubleshooting on live robotic systems.
Troubleshooting - Troubleshooting Process
Explain the troubleshooting process when diagnosing systems including the specific steps to be taken to ensure the problem is verified, identified, and corrected. Include the follow-up process to ensure the equipment problem has been properly corrected, verified, and documented.
List the various ways systems may be monitored (electronically and physically) and how feedback systems can be utilized to identify, diagnose, and correct the root cause(es) of the problem.
Demonstrate where and how to view event messages, error codes, fault messages, alarm messages, warning messages, etc.
Demonstrate troubleshooting and repairing a system based on error code analysis, probable causes, and recommended actions from program diagnostics and manufacturer documentation.