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.

Qualifications

Qualifications

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Education and Experience

1. High school diploma or general education degree (GED).
2. One to three months related experience and/or training; or equivalent combination of education and experience.
3. Prior experience operating a CNC press brake or other metal forming equipment preferred.
4. Forklift operator training certificate (obtained through KMW training); must be maintained.

Required Technical Skills

1. Ability to read and understand blueprints, drawings, program sheets, and work orders, including bend lines, angles, and flange dimensions.
2. Ability to use measuring devices such as tape measures, calipers, micrometers, and protractors or angle gauges, in both inches and millimeters.
3. Ability to operate numeric control (CNC) touch screen controls.
4. Ability to add, subtract, multiply, and divide using whole numbers, fractions, and decimals, and to work with angles, units of weight, and both American and metric distance.
5. Mechanical aptitude, including the ability to install and align punches, dies, and backgauges and to recognize worn or damaged tooling.
6. Ability to safely operate an overhead crane to load and position material.
7. Working knowledge of shop safety practices, including PPE, machine guarding, and lockout/tagout, through completion of required safety training.

Required Soft Skills

1. Strong attention to detail and commitment to producing accurate, quality parts.
2. Ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form, and to solve problems involving several concrete variables in standardized situations.
3. Ability to read and comprehend written instructions and safety procedures, write simple production notes, and communicate effectively with supervisors, programmers, and co-workers.
4. Ability to stay focused and maintain a steady pace during repetitive production work.
5. Willingness to learn, accept feedback, and cross-train on additional equipment.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is regularly required to stand; walk; use hands to finger, handle, or feel; reach with hands and arms; climb or balance; stoop, kneel, crouch, or crawl and talk or hear.

The employee must frequently lift and/or move up to 25 pounds and occasionally lift and/or move up to 50 pounds. Heavier material and parts are moved with an overhead crane or forklift. Specific vision abilities required by this job include close vision, depth perception and ability to adjust focus.

Work Environment

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is regularly exposed to fumes or airborne particles, extreme heat and vibration. The employee is frequently exposed to moving mechanical parts and toxic or caustic chemicals. The noise level in the work environment is usually loud to very loud. Required PPE includes safety glasses, hearing protection, gloves, and safety-toe footwear.

Strength Level Classification Criteria

The Strength Level Classification Criteria of this job as established by the US Department of Labor:

Level 3: Medium Work – Exerting 20 to 50 pounds of force occasionally, and/or 10 to 25 pounds of force frequently, and/or greater than negligible up to 10 pounds of force constantly.

Safety Rules and Regulations

All Safety Rules and Regulations will be followed. Those specifically associated with this job are:

03.44.01 General Safety Rules and Regulations

03.44.02 Lifting

03.44.03 Forklift

03.44.06 Hand and Power Tools

03.44.07 Housekeeping

03.44.08 PPE

03.44.10 Machinery and Equipment

Job Safety Analysis

The safety committee conducts surveys and develops Job Safety Analysis for all company jobs. The JSA specifically for this job is:

03.46.21 Brake Press Operation (Accurpress and LVD)

Reporting

The Numeric Controlled Machine (NCM) Operator reports to the Fabrication Foreman II.

Responsibilities

This job description is not intended to be an exhaustive list of all duties, responsibilities, or qualifications associated with the position. Duties, responsibilities, and activities may change, or new ones may be assigned at any time with or without notice.