Tool and Die Maintenance
Hybrid-based
ONET: 49-9041.00
3
Years
265
Skills
1532h
Related instructions
6000h
On-the-job training
Classroom instruction topics
- Introduction to Machine Shop I
- Introduction to Machine Shop I Lab
- Introduction to Machine Shop II
- Introduction to Machine Shop II Lab
- Milling I Lab
- Precision Measurement
- Manufacturing Safety Practices
- Quality Control Concepts
- Intro to Thermal/Electrical Principles
- Fluid Systems
- CAD Concepts / Intro to 3D Modeling
- Basic Blueprint Reading for Machinists
- Basic CNC Milling I
- CNC Milling Lab I
- Die Fundamentals
- Basic Formability
- Precision Grinding
- Precision Grinding Lab
- Welding - Special Topics
- English Composition I
- Intro to Tech. Math
- Humanities/Fine Arts (excluding Speech & Foreign Language)
- Social & Behavioral Science
- Natural Science or MTH elective
- Mazda Toyota - Welding, Finish, Punching Finish
- Mazda Toyota - Trim finishing in three levels, Producing standard trim edge
- Mazda Toyota - Flat Grinding and Finishing
- Mazda Toyota - Bead Shaping
- Mazda Toyota - Globe Punch Finish, 1500R Shape Side Finish
On-the-job training
- OJT Hours
- Workplace safety knowledge and implementation
- Explain and work with the safety essentials of the mating procedure
- Consistently wear PPE and explain the functions of the protective equipment needed for the job
- Explain and implement 4S
- Explain and practice KY
- Make near miss suggestions
- Suggest improvements in safety
- Safely perform low frequency work in the assembly
- Point out the full range of anxiety and behavior within the group
- Check the function of safety devices
- Ensure that the opening inspection can be done
- Explain the safety standards of the operation
- Explain the imperative for safety at work
- Observe the work and point out all states of anxiety and behavior
- Explain what to look for in a state of anxiety and can improve it
- Use tools for measuring workpieces
- Calculate measurements using a scale
- Calculate measurements with a caliper
- Calculate measurements using a height gauge
- Calculate measurements using a micrometer
- Calculate measurements using a dial gauge
- Use the scoring system
- Calculate measurements using a block gauge
- Use pressure-sensitive paper to measure the adhesion of distance plates, etc.
- Use a plate thickness measuring instrument to measure plate thickness reduction
- Measure the forming margin using the scribed circle test
- Use tools and jigs proficiently
- Use different types of air tools depending on the purpose
- Use different grinding wheels for different purposes
- Use different jigs and tools for manual cutting and polishing operations
- Demonstrate efficient use and handling of different jigs and tools
- Reliably perform daily inspection of jigs and tools
- Manage jigs and tools
- Read and draw diagrams
- Read and explain prints and electrical diagrams
- Read and explain data diagrams
- Read and explain configuration diagrams
- Read and explain mold drawings
- Effectively participate in the mold drawing review meeting
- Draw simple request diagrams for machining
- View a data diagram and write out the changes
- View a diagram and draw out the changes
- Trigonometrically draw the machining request diagram of the modified part by looking at the data diagram
- Understand the machining request diagram of the change part by looking at the change diagram
- Basic equipment operations
- Explain the functions of and operate the Tri-Press
- Perform a start-up inspection of the Tri-Press
- Respond to any problems that may arise in the Tri-Press
- Explain the function of and operate a steel plate bending machine
- Properly inspect the steel plate bending machine at the beginning of the day
- Effectively respond to problems related to steel plate bending machines when they occur
- Explain the function of and operate a steel plate cutting machine
- Properly inspect the steel plate cutting machine at the beginning of the day
- Effectively respond to problems related to steel plate cutting machines when they occur
- Perform work quality checks
- Verify measurements of workpiece using a micrometer
- Verify measurements of workpiece using a dial gauge
- Use the scoring system to determine accuracy of measurements
- Verify measurements of workpiece using a block gauge
- Use pressure-sensitive paper to measure the adhesion of distance plates, etc.
- Use a plate thickness measuring instrument to measure the plate thickness reduction of the workpiece
- Measure the forming margin of the workpiece using scribed circle test
- Disassembly and assembly work operations
- Determine the correct tools to use per job; as listed under Job Function 3
- Disassemble and assemble rotary cams and double cams
- Conduct a crane inspection at the beginning of the day
- Effectively respond to crane related problems when they occur
- Effectively respond to hoist-related problems when they occur
- Die internal device operations
- Repair or replace air cylinders
- Repair or replace nitro cylinders
- Replace the pipes of the nitrogen gas cylinder
- Replace proximity switches and wiring
- Explain how the interlock works
- Perform replacement, wiring and adjustment of the nitrogen gas pressure monitor
- Perform improvements and modifications of in-mold equipment
- Perform improvements and modifications of electrical wiring of in-mold equipment
- Draw process
- Examine the panel and fix the galling area
- Examine the panel and fix the cracks
- Perform 4S on the outside plate
- Track down the source of the defect
- Perform outer and inner sliding of inner and outer panel parts
- Adjust the distance blocks
- Regulate the amount of material flow by adjusting the beads during molding
- Correct the surface of the punches on the outer panel
- Work panel before and after the surface treatment
- Trim process
- Adjust clearance of thin products
- Adjust clearance for thicker materials
- Match the lower die and panel shape
- Perform panel shape matching
- Adjust the timing of the cutting edge
- Adjust the timing of the hole punch
- Correct extraction distortions
- Perform adjustments to trim process per mold
- Slide the putt and the punching die together
- Flange Process
- Adjust clearance of thin products
- Adjust clearance for thicker materials
- Match the lower die and panel shape
- Perform panel shape matching
- Adjust the timing of the curved blade
- Correct the shakure (distortion)
- Perform adjustments to flange process per mold
- Correct the curved blade culling
- Adjust putt-press surface contact
- Cam flange process
- Adjust clearance of thin products
- Adjust clearance for thicker materials
- Match the lower die and panel shape
- Perform panel shape matching
- Adjust the timing of the curved blade
- Correct wrinkles during the secondary restriking process
- Correct distortions during secondary molding
- Adjust pad-press surface contact
- Perform sudden repair work
- Examine the panel and fix the galling area
- Examine the panel and fix the cracks
- Perform 4S on the outside plate
- Track down the source of the defect
- Perform outer and inner sliding of inner and outer plate parts
- Adjust the distance plate
- Regulate the amount of material flow by adjusting the beads during molding
- Correct the surface of the punches on the outer plate
- Countermeasure die before and after the surface treatment
- Adjust clearance of thin products
- Adjust clearance for thicker materials
- Match the lower die and panel shape
- Perform panel shape matching
- Improvement and modification
- Examine the panel and fix the galling area
- Examine the panel and fix the cracks
- Perform 4S on the outside panel
- Track down the source of the defect
- Perform outer and inner sliding of inner and outer plate parts
- Adjust the distance plate
- Regulate the amount of material flow by adjusting the beads during drawing
- Correct the surface of the punches on the outer panel
- Countermeasure die before and after the surface treatment
- Adjust clearance of thin products
- Adjust clearance for thicker materials
- Match the lower die and panel shape
- Perform panel shape matching
- Adjust the timing of the cutting edge
- Arc welding operations
- Adjust current of the welding machine as needed
- Choose the correct welding rod according to job need
- Demonstrate satisfactory butt welds
- Raise cutting edge and curved edge
- Determine the amount of weld to complete the job
- Determine coining area for hard contact
- Build up the shape of the punch
- Weld bead area for gaining control
- Make a metal gain area on the outer punch
- Alter the shape of equipment and data, etc. during the buildup
- Operate a preheating furnace and explain the process of operation
- Inspect preheating furnace at the beginning of the day
- Effectively respond to preheating furnace problems
- Tig welding operations
- Adjust current of the welding machine as needed
- Choose the correct welding rod according to job need
- Demonstrate satisfactory butt welds
- Raise cutting edge and curved edge
- Build up the shape of the punch
- Weld bead area for gaining control
- Make a metal gain area on outer punch
- Die inspection operations, draw process
- Inspect and replace each slide plate
- Inspect N2 cylinder hose
- Determine plating status
- Gauge deformation and wear of die
- Inspect bolt tightening state
- Verify mold proximity (looseness, breakage, position)
- Die inspection operations, post-engineering
- Inspect scrap cutters
- Inspect bolt tightening state
- Inspect upper and lower cutting edge condition (blade chipping, wear, second condition)
- Inspect N2 cylinder and hoses
- Inspect cams (slide plate, guide bar, forced return, urethane stripper)
- Inspect upper plate (wear, deformation)
- Inspect Pad (cracks, wear and tear)
- Replace the slide plate (due to wear and scuffing)
- Inspect double cams, rotating cams. Perform operation check
- Inspect inside the lifter (spring, urethane, guide)
- Perform sub-lifter operation check
- Abnormal treatment, line support
- Correct galling
- Treat a split / elongation
- Treat wrinkles and distortions
- Treat panel burrs
- Perform a shock line procedure
- Treat the recesses by holding down the foreign object
- Respond to shortcuts
- Deal with scrap clogging and poor flow
- Treat burrs and blade chatter
- Correct lifter malfunction
- Perform heat treatment
- Respond to cylinder-related defects
- Effectively resolve a cam actuation malfunction
- Adjust cam joint level (when not possible to grind or cut on the side of the punch with a simultaneous roof rail)
- Perform per-mold procedures
- Perform procedures related to in-mold devices
- Provide opinions on problems to the line and quality staff
- Prevent recurrence of problems
- Abnormal treatment, investigation / countermeasures
- Perform effective action at the time of equipment failure
- Implement corrective measures when the upper die does not fit in at the time of die assembly
- Implement corrective measures when the upper part of the mold cannot be separated during mold disassembly
- Cross cut operations, general
- Explain the principles of cross cutting
- Remove pressure-sensitive paper before cross-cutting
- Determine the cross-cutting range
- Clean cross-cut surfaces with an adhesive roller
- Correctly determine pass/fail status of the mold face
- Select the appropriate sandpaper for the job
- Perform necessary finishing touches
- Cross cut operations, tap weld modifications
- Correct the tapping out of the area being held down
- Use scale to check repair
- Select matching wheels
- Perform grooving with a blade tool
- Accurately determine the extent of the build-up
- Adjust the last tri-press
- Explain the correct process for making adjustments of tri-press
- Grinding operations, drumming out
- Identify and mark the extent of the recesses with a sash and scale
- Explain tapping procedures and demonstrate the main points of work
- Grind out uniformly by standard spacing
- Judge the degree of unevenness of a polished part by using a sandpaper and a scale
- Grinding operations, weld correction
- Select the welding rod according to the material
- Use the scale and luminosity to determine and mark the weld area prior to welding
- Proficiently use sander and apply it only to the welded area
- Finish the job while avoiding high areas
- Implement 4S after the mold correction is completed
- Electrical correction
- Explain the current situation in wiring
- Verify the type investigation procedure is well established
- Ensure wiring is in good condition before taking action
- Explain how to counteract situation
- Use the standard wiring diagram
- Confirm work with tester
- Quality assurance operations
- Explain the purpose and criteria for guide plate measurement and adjusting defective parts
- Explain the role and criteria of DB and adjust defective parts
- Control the conditions of good products against defects such as knots and cracks
- Present an evaluation of personal administrative capabilities regarding quality operations
- Die operations
- Explain all-heat treated steel
- Track spare parts
- Perform inspection of the mold and maintenance to find defects
- Track down the root cause of trim splits
- Explain the process of welding hardened steel
- Restore damaged, fully tempered steel by pre-heating and post-heating after welding
- Lathe operations
- Correctly identify the different lathe bits used for different types of workpieces and demonstrate how to change the tips
- Select the correct feed and rotation speed according to the workpiece
- Demonstrate how to properly drill with a lathe
- Cut the thread using a lathe
- Measure the size of a hole punch
- Perform outside diameter (OD) machining
- Perform inside diameter (ID) machining
- Process urethane to correct specification
- Use a lathe to cut and process workpieces
- Turn tapers
- Manage tool scrap, chips and drill scrap
- Manage lathe operations to complete jobs
- Perform cutting along the line of marking
- Requisition proper material to complete job
- Drill and turn work piece
- Explain setup and operation
- Correctly machine a groove
- Demonstrate proper operation of lathe cutting tools
- CNC Processing Machine
- Explain the general rules of lockout, heavy objects, operating range, etc.
- Demonstrate proficient use of G-code programming
- Demonstrate proficient use of M-code programming
- Explain function of structure, curved surfaces and PF cutting tools
- Explain and demonstrate blade assembly procedures
- Demonstrate the ability to operate a machine control panel
- Perform manual machining operations (rapid traverse, cutting feed and manual operation)
- Conduct MDI operation (ATC, AAC)
- Correctly feeding cutters into the magazine
- Perform the parallelization and centering (X, Y, Z) procedures
- Create data with Work NC
- Set the processing origin
- Lead meeting about CNC machine
- Correctly select a blade tool
- Perform startup and machining confirmation
- Adjust processing operations
- Perform actual processing (thrust and helical)
- Process curved surfaces
- Explain proper procedure to following case of emergency
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