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):
?
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.
?
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.
?
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.
?
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.
?
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.
?
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):
?
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.
?
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.
?
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.
?
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.
?
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.
?
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):
?
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.
?
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.
?
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.
?
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.
?
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
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