CNC Setter/Operator/Programmer

Machining Setter
Experience : 5yrs above
(Contact Mounika -HR 9962173024)

Roles & Responsibilities:
1. Machine Setup: Set up machines, including loading programs, tool changes, fixture setups, and machine calibrations.

2. Tool Selection: Machine Setup: Setting, programming, tool selection, fixture setups

3. Machine Calibration: Ensure that the machine is properly calibrated and aligned to maintain precision.

4. Safety Compliance: Follow all safety protocols and ensure that safety measures are in place before starting machine operations.

5. Monitor Operations: Oversee the production process, ensuring that the machine runs smoothly and performs according to the specifications.

6. Supervise Operators: Monitor, train, and supervise operators as needed to ensure compliance with best practices and continuous improvement standards.

7. Quality Control: Monitor the machining process for defects, adjust parameters as needed, and inspect the initial parts for accuracy.

8. Troubleshooting: Identify and resolve any issues or malfunctions that may occur during machining.

9. Documentation: Maintain accurate records of setups, tool usage, and production runs.

10. 5S: Maintain an organized, clean workspace by sorting, organizing, cleaning, standardizing, and sustaining practices.

11. Kaizen: Identify improvements, optimize programs, and reduce setup time for continuous process enhancement.

Key Performance Indicators (KPIs):

Ø Machine Downtime: Track the amount of time the machine is down due to setup errors, maintenance, or tool issues.

Target: ≤ 5% of total operating time per machine.

Minimizing downtime is essential for maximizing machine utilization.

Ø First-Pass Yield: Percentage of parts that pass inspection on the first run without the need for rework.

Target: ≥ 95% of parts pass the first inspection without rework.

High first-pass yield reflects precision setup and correct machine calibration.

Ø Setup Time Efficiency: Time taken to set up machines vs. standard or ideal setup times.

Target: Setup time should be ≤ 10% of the total production time.

Reducing setup time increases overall productivity.

Ø Tool Life Management: Efficiency in managing the lifespan of tools, reducing tool change frequency.

Target: Tool life optimization, reducing tool changes by 10% per month.

Extending tool life reduces tool cost and machine downtime.

Ø Productivity Rate: Number of components produced per hour/day, considering setup times and machine availability.

Target: ≥ 90% of planned production output.

Ensuring that the setter achieves or exceeds the target production volume.

Ø Quality Control: Number of defects per batch or per machine cycle.

Target: ≤ 2% defects per batch.

Fewer defects per batch indicate accurate machine setup and efficient monitoring.

Programmer

1. Program Creation: Develop programs for machining operations based on blueprints, 3D models, and technical specifications.

2. G-Code and M-Code Writing: Write and test G-code for machine operations to ensure they are optimized for speed, efficiency, and precision.

3. Optimize Programs: Modify programs to enhance performance, reduce cycle times, and improve machine utilization.

4. Tooling Selection: Choose appropriate tooling and machine parameters based on the part design and material.

5. Simulation: Run simulations to ensure the program runs smoothly without causing machine crashes or part defects.

6. Collaboration: Work closely with setters and operators to ensure smooth integration between programming and machine setup.

7. Documentation: Maintain detailed records of programs, tool paths, and operational changes.

8. 5S: Maintain an organized, clean workspace by sorting, organizing, cleaning, standardizing, and sustaining practices.

9. Kaizen: Identify improvements, optimize programs, and reduce setup time for continuous process enhancement.

Key Performance Indicators (KPIs):

Ø Programming Time: Time taken to create and test programs for a new part or project.

Target: ≤ 5% variance from the estimated programming time.

Efficient programming helps improve overall workflow and minimizes delays.

Ø First-Time Right Programming: Percentage of programs that run successfully on the first attempt without significant changes.

Target: ≥ 98% of programs run successfully on the first attempt.

Reducing reprogramming or adjustments increases production efficiency.

Ø Program Efficiency: Reduction in machine cycle times and optimization of tooling and processes.

Target: ≥ 5% improvement in cycle time through programming optimization.

Program optimization leads to higher machine throughput and reduced cost per part.

Ø Error Rate: Number of programming errors that result in rework, scrap, or production delays.

Target: ≤ 1% errors related to programming causing downtime or defects.

A low error rate ensures that the programs are reliable and robust.

Ø Cycle Time Improvement: Percentage improvement in machine cycle time through effective programming and optimization.

Target: Achieve at least a 5% reduction in cycle times every 3 months.

Reducing cycle time directly affects machine throughput and overall productivity.

Ø Production Output: Number of parts produced per program, reflecting the effectiveness and efficiency of the program.

Target: ≥ 98% of parts produced per program within expected output range.

This shows that the programs are accurately aligned with production goals.

Setter-Cum-Programmer

1. Programming and Setup: Combines the roles of both Setter and Programmer by writing programs and setting up the machines for production.

2. Tool Selection and Setup: Select and set up the necessary tools for the machining process based on the part requirements.

3. Machine Calibration and Programming: Ensure that the machine is properly calibrated, and the program is properly loaded, tested, and optimized.

4. Operations Monitoring: Supervise the machining process, making real-time adjustments to improve efficiency, reduce downtime, and maintain part quality.

5. Troubleshooting and Optimization: Resolve issues related to both programming and machine setup and optimize processes for maximum efficiency.

6. Training: Train operators and setters on machine setup, program usage, and troubleshooting procedures.

7. Documentation: Maintain records of program modifications, machine setups, and production details for future reference.

8. 5S: Maintain an organized, clean workspace by sorting, organizing, cleaning, standardizing, and sustaining practices.

9. Kaizen: Identify improvements, optimize programs, and reduce setup time for continuous process enhancement.

Key Performance Indicators (KPIs):

Ø Dual Role Efficiency: Time spent on both programming and machine setup, compared to individual role efficiency.

Target: ≤ 10% combined time for both programming and setup.

Balancing both roles efficiently can reduce overall lead times and increase machine utilization.

Ø Setup Time Reduction & Accuracy: Time taken for both setup and program creation, with a focus on reducing overall setup time. Percentage of successful program runs and setup correctness without the need for adjustments.

Target: ≥ 95% accuracy in both setup and program execution without rework.

Accuracy is crucial in ensuring the parts are machined correctly and production runs smoothly.

Ø Machine Utilization: Efficiency in utilizing the machine’s time for production, with minimal downtime due to setup or programming errors.

Target: ≥ 85% machine uptime with minimal interruptions.

High utilization rates help maximize the return on investment in CNC machinery.

Ø Defect Rate: Percentage of defects or rework required due to programming or setup issues.

Target: ≤ 1% of parts requiring rework due to setup or programming issues.

Maintaining a low defect rate ensures parts are produced to specification and reduces waste.

Ø Cycle Time Reduction: Improvements in machining cycle times, reflecting both programming and setup optimizations.

Target: ≥ 5% reduction in total cycle time due to combined optimization of setup and programming.

Faster production leads to more units produced in less time, increasing productivity.

Over-all KPI Targets (For Production Department):

1. OEE (Overall Equipment Efficiency): A high OEE reflects well-maintained equipment, optimized processes, and productive workforce.

Target: ≥ 85% OEE.

2. Scrap Rate: Minimizing scrap is essential to reduce material waste and enhance cost efficiency.

Target: ≤ 2% of total production.

3. On-Time Delivery: Ensuring products are delivered on time meets customer expectations and reduces operational delays.

Target: ≥ 98% on-time delivery.

4. Maintenance Interventions: Minimizing unexpected maintenance ensures smooth operations and reduced downtime.

Target: ≤ 2 unplanned maintenance events per month per machine.

Job Types: Full-time, Permanent

Pay: ₹30,000.00 - ₹40,000.00 per month

Benefits:

• Food provided
• Provident Fund

Work Location: In person