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SUMMARY

Responsible for the expedient and high-quality production of specialty machined components used in TERRA SONIC’s drilling equipment and supporting products. Also charged to be responsive to the needs of TERRA SONIC’s internal customers. Supports the research & development (R&D) function of the company.

ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned.

Communications

· Reads and comprehends instructions and correspondence; asks appropriate questions and performs the instructed task.

· Effectively and respectfully communicates with supervisor and coworkers in verbal and written formats.

· Effectively presents information in one-on-one and small group situations.

· Influences and encourages a free flow of information between employees and management.

· Effectively teaches technical and nontechnical aspects of jobs to employees with various levels of experience.

· Acts as a role model in the communications with employees and management.

· Holds ultimate accountability for communications within their work cell.

Documentation

· Enters time-clock and work order activity into Global Shop work station in a timely manner.

· Accurately enters work order transactions into GSS; pieces produced, material issued, and scrap parts.

· Completes all required process documentation in a coherent, legible and timely manner.

Leadership

· Acts in a respectful manner to clients, coworkers and supervisors.

· Demonstrates a desire to progress in the company by taking initiative and assuming additional responsibilities.

· Travels as required.

· Demonstrates dependability through an excellent attendance record and timeliness; works overtime as needed or required.

· Demonstrates troubleshooting and problem resolution skills.

· Assists newer employees with work related issues through effective teaching, training and mentoring.

· Ensures the availability of process consumables by verifying inventory and notifying appropriate personnel of shortages.

· Assists in the development of employees to further their ability to become more proficient in their respective jobs and facilitate their career growth.

· Provides sound and consistent project and people leadership within work cell or department.

· Orients new employees in work cell practices.

· Effectively leads employees while adhering to company policies and processes.

Production

· Manages own time to ensure he/she remains productive.

· Capable of working independently and with others.

· Conscientious about work quality.

· Consistently meets or exceeds job specific production goals.

· Displays initiative in maintaining productive activity during machine cycle time.

· Effectively and consistently takes responsibility for all work cell activities.

· Troubleshoots production issues to reduce down time and improve safety.

· Updates process documentation to ensure lessons learned are carried forward.

Safety and Risk Management

· Uses appropriate safety equipment and personal protection equipment.

· Accepts accountability for own conduct and obligations.

· Regularly follows all of Terra Sonic’s safety policies as described in the Health & Safety Procedures Handbook.

· Diligently follows all supplemental policies on which training has been provided.

· Demonstrates consistent awareness for safety and risk issues.

· Demonstrates an understanding of industry practices and applicable regulations.

· Performs daily inspections of work area and participates in the resolution of safety concerns and/or equipment issues.

· Ensures the well-being of coworkers by teaching and promoting safety rules and regulations.

Technical – General

· Demonstrates self-motivation, self-discipline and attention to detail.

· Operates forklift to move material and perform equipment change-over/set up.

· Performs periodic preventive maintenance activities on equipment.

· Demonstrates advanced mechanical aptitude and reasons through mechanical problems in a logical manner.

· Performs basic maintenance and repairs to in-plant equipment.

· Through hands-on experience and course work, acts as the content expert on projects.

· Plans, leads and executes projects in a manner ensuring safety and efficient time management.

· Able to anticipate and foresee issues with blueprints and schematics prior to the start of projects, and takes appropriate corrective action.

Technical – Job-Specific

· Reads process sheets, blueprints, and sketches of part to determine required machining, dimensional specifications, set up and operating requirements.

· Understands the functions of each CNC machine and matches machine capability with product requirements.

· Ability to operate CNC machines and performs basic set ups (lathe & mill).

· Observes machine operation to detect workpiece defects or machine malfunction.

· Creates and/or edits CNC programs to match product requirements; geometry, speed, feed, G&M codes.

· Ability to operate secondary equipment, e.g., drill press, engine lathes, vertical mills, iron worker, etc.

· Proficient working with raw various materials including; rough machined blanks, castings, forgings, and bar stock, etc.

· Knowledgeable of MasterCam (or similar) CAD/CAM software; understanding of multiple-axis programming; interprets “G” & “M” code output.

· Develops CNC programs for producing component geometry as specified on drawings.

· Selects cutting inserts, tool holders, and work holding to support machining strategy.

· Within the CNC program, tool paths and machining sequences are chosen which will facilitate Quality/Process control.

· Identifies the optimal metal removal parameters (speed, feed, depth of cut) for metallurgical properties of the part to be machined while taking into consideration the rigidity of the set-up.

· Assists Engineering/R&D efforts to continuously improve upon TERRA SONIC’s existing processes and develop new technologies.

· Manages new part development starting with concept drawings, machining of prototypes, facilitating design refinements, and locking down a process that meets quality and cost targets.

· Through analysis of a component’s functionality, machinery capability, raw material selection, and manufacturing process; identify cost reduction strategies and/or product enhancement opportunities.

Process Improvement

· Possesses an understanding of Lean Manufacturing Principles; eliminate waste, visual management, set up time reduction (SMED), etc.

· Maintain a clean and organized work area (5s).

· Actively support continuous process improvement (Kaizen); always, always look for ways to refine the process.

· Develop process documentation (set up sheet, tooling list, inspection plan, CNC program) that are congruent with the principles of Standard Work.

· Evaluate process performance data to identify process variation, and take appropriate steps to reduce variation.

· Lead process improvement projects to eliminate waste and reduce process variation.

· Build robust processes capable of meeting six-sigma defect rates.

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/or Experience

• High school diploma or general education degree (GED); or
• One to three months related experience and/or training; or equivalent combination of education and experience

Certificates, Licenses, and/or Registrations

· Forklift operator certificate required

Language Skills

• Read and interpret documents such as safety rules, operating and maintenance instructions, and procedure manuals
• Write routine reports and correspondence
• Effectively speak before groups of customers or employees of organization

Mathematical Skills

• Add, subtract, multiply, and divide in all units of measure, using whole numbers, common fractions, and decimals
• Compute rate, ratio, and percent and to draw and interpret bar graphs

Reasoning Abilities

• Apply common sense understanding to carry out instructions furnished in written, oral, or diagram form
• Deal with problems involving several concrete variables in standardized situations

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.

Performance of this job requires the employee to:

· Regularly reach with hands and arms

· Frequently stand; use hands to finger, handle, or feel; climb or balance; stoop, kneel, crouch, or crawl; talk or hear; and taste or smell.

· Occasionally walk and sit

· Must frequently lift and/or move up to 25 pounds, occasionally lift and/or move up to 50 pounds

· Exhibit specific vision abilities which include but are not limited to close vision, distance vision, color vision, peripheral 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.

Performance of this job requires the employee to be:

· Frequently exposed to moving mechanical parts and outside weather conditions

· Occasionally exposed to wet and/or humid conditions; high, precarious places; fumes or airborne particles; toxic or caustic chemicals; extreme cold; extreme heat; risk of electrical shock; explosives; risk of radiation; and vibration

· Frequently exposed to a loud noise level in the immediate work environment