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Key Responsibilities and Required Skills for Gear Machinist

💰 $25 - $45 / hour

ManufacturingSkilled TradesMachiningIndustrial

🎯 Role Definition

As a Gear Machinist, you are the expert artisan at the heart of our production process. You will be responsible for setting up, operating, and maintaining specialized CNC and manual gear manufacturing equipment to produce intricate and high-tolerance gears. This position requires a blend of technical expertise, analytical thinking, and a meticulous eye for detail. You will work independently and collaboratively to transform raw materials into critical components that meet the industry's most demanding specifications, ensuring the reliability and performance of the final products.

📈 Career Progression

Typical Career Path

Entry Point From:

  • CNC Machinist
  • Machinist Apprentice
  • General Machinist

Advancement To:

  • Lead Machinist / Cell Lead
  • CNC Programmer
  • Manufacturing Supervisor / Manager
  • Quality Inspector / CMM Programmer

Lateral Moves:

  • Tool and Die Maker
  • Prototype Machinist
  • Field Service Technician

Core Responsibilities

Primary Functions

  • Set up, operate, and maintain a variety of CNC gear manufacturing machines, including gear hobbers, shapers, and grinders (e.g., Gleason, Liebherr, Pfauter, Reishauer).
  • Interpret complex engineering blueprints, drawings, and technical specifications with a strong proficiency in Geometric Dimensioning and Tolerancing (GD&T).
  • Perform intricate machine setups for diverse gear types such as spur, helical, bevel, and worm gears, ensuring correct tooling, fixtures, and program parameters.
  • Conduct first-piece, in-process, and final inspections using a wide array of precision measuring instruments, including micrometers, calipers, bore gauges, and indicators.
  • Utilize specialized gear inspection equipment, such as CMMs with gear-checking software or dedicated M&M gear checkers, to verify profile, lead, pitch, and runout.
  • Edit CNC programs directly at the machine controller (e.g., Fanuc, Siemens) to adjust offsets, optimize tool paths, and improve overall part quality and cycle time.
  • Monitor machining processes continuously, listening for auditory cues and observing machine performance to anticipate and correct issues like tool wear or chatter.
  • Calculate and verify critical gear data and machine settings using advanced shop mathematics, including trigonometry and gear-specific formulas.
  • Troubleshoot and resolve complex machining problems, diagnosing root causes for dimensional inaccuracies, surface finish defects, or machine alarms.
  • Select, install, and maintain appropriate cutting tools, hobs, and shaper cutters, ensuring they meet sharpness and dimensional requirements for each job.
  • Perform routine and preventative maintenance on machinery, including lubrication, cleaning, and fluid level checks, to ensure operational readiness and prevent downtime.
  • Handle and machine a variety of materials, from common alloy steels to exotic metals and high-performance plastics, understanding their unique machining characteristics.
  • Maintain a meticulously clean, organized, and safe work environment by adhering to 5S principles and all company safety policies and procedures.
  • Document production activities and quality data with high accuracy, using manufacturing execution systems (MES), paper logs, and statistical process control (SPC) charts.
  • Collaborate effectively with manufacturing engineers, CNC programmers, and quality assurance teams to resolve production issues and support new product introductions (NPI).
  • Deburr and finish machined gears using manual and automated methods to meet stringent surface finish and edge break requirements.
  • Operate overhead cranes, jib cranes, and forklifts to safely handle and position heavy workpieces, fixtures, and raw materials.
  • Participate actively in continuous improvement initiatives, such as Kaizen events and lean manufacturing projects, to enhance efficiency and reduce waste.
  • Provide technical guidance, mentorship, and on-the-job training to machinist apprentices and less experienced operators.
  • Read and meticulously follow detailed work instructions, setup sheets, and standard operating procedures (SOPs) for all tasks.
  • Verify gear tooth quality, including contact patterns using bluing compound, and make necessary machine adjustments for optimal meshing.

Secondary Functions

  • Support continuous improvement projects, actively participating in Kaizen events and process optimization workshops.
  • Collaborate with the quality and engineering departments to perform root cause analysis on non-conforming parts.
  • Assist in the training and mentorship of machinist apprentices and new team members.
  • Maintain accurate and detailed logs of production runs, machine maintenance, and inspection results.

Required Skills & Competencies

Hard Skills (Technical)

  • Gear Manufacturing Processes: Expertise in gear hobbing, shaping, grinding, and lapping techniques.
  • CNC Machine Operation & Setup: Proficiency with brands like Gleason, Liebherr, Pfauter, Fanuc, and Siemens controls.
  • Blueprint Reading & GD&T: Advanced ability to interpret complex engineering drawings and geometric tolerances.
  • Precision Measurement & Inspection: Mastery of micrometers, calipers, bore gauges, and specialized gear-checking equipment (CMM, M&M).
  • CNC Program Editing: Ability to read and make adjustments to G-code and M-code at the machine controller.
  • Shop Mathematics: Strong skills in algebra, geometry, and trigonometry for calculating machine settings and part dimensions.
  • Tooling Knowledge: Deep understanding of cutting tools, hobs, and cutters, including selection, preparation, and maintenance.
  • Machine Troubleshooting: Ability to diagnose and resolve mechanical, tooling, and process-related issues.
  • Material Properties: Knowledge of the machinability of various metals, including carbon steel, stainless steel, and alloys.
  • Safety Procedures: Familiarity with lockout/tagout (LOTO), crane operation, and general machine shop safety.

Soft Skills

  • Exceptional Attention to Detail: A meticulous nature is essential for producing high-precision components.
  • Problem-Solving: Strong analytical and critical thinking skills to diagnose and resolve complex issues.
  • Time Management: Ability to prioritize tasks and manage workflow efficiently in a production environment.
  • Self-Motivation & Work Ethic: A dependable, proactive individual who can work effectively with minimal supervision.
  • Communication Skills: Ability to clearly communicate technical information with team members, engineers, and supervisors.
  • Teamwork & Collaboration: A cooperative mindset focused on achieving team and company goals.
  • Adaptability: Flexibility to work on different machines, handle changing priorities, and learn new processes.

Education & Experience

Educational Background

Minimum Education:

  • High School Diploma or GED.
  • Completion of a registered machinist apprenticeship program or a certificate from a technical/vocational school in Machining.

Preferred Education:

  • Associate's Degree in Machine Tool Technology, Manufacturing Technology, or a related field.

Relevant Fields of Study:

  • Machining Technology
  • Manufacturing Engineering Technology
  • Industrial Technology

Experience Requirements

Typical Experience Range: 3-5 years of hands-on experience as a CNC Machinist in a precision manufacturing environment.

Preferred: 5+ years of direct, dedicated experience setting up and operating gear manufacturing equipment (hobbing, shaping, grinding). Demonstrable experience with specific machine tool brands (e.g., Gleason, Pfauter, Liebherr) is highly desirable.

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