Machinist
Competency-based
ONET: 51-4041.00
1
Years
238
Skills
765h
Related instructions
Classroom instruction topics
- Geometry Algebra
- Intro to Machine Tool
- Geometry Dimensions & Tolerance
- Intro to CAD
- Material SCI - Metallurgy
- Machine Tool Setup - Operation
- Manufacturing Process
- Advanced Machining Process
- G&M Code CNC Programming
- 2D & 3D Computer Machining
- Basic Blue Print Reading
- Advanced Trigonometry & Angle
- Plane Trigonometry
- Industrial Safety
- Intro to CNC
On-the-job training
- Basic Mechanical Power Transmissions
- Mechanical Drives - Perform chain drive system identification and visual inspection.
- Prepatory Work - Perform lockout/tagout, blockout, and release of stored energy requirements using proper procedures.
- Prepatory Work - Explain common hazards and identify associated personal protective equipment (PPE).
- Prepatory Work - Select the correct tool for a job or activity.
- Shafts & Couplings - Identify the different functions of shafts.
- Shafts & Couplings - Identify the types of couplings used in mechanical systems and describe the functions of each.
- Prepatory Work - Match components utilizing information on a blueprint.
- Bearings and Seals - Identify and describe various types of seals.
- Shafts & Couplings - Maintain and troubleshoot various types of coupling systems.
- Bearings and Seals -Troubleshoot and install- Plain bearings- Ball bearings- Roller bearings- Angular contact bearings- Associated seals
- Shafts & Couplings - Demonstrate the installation of various types of coupling systems.
- Shafts & Couplings - Align various types of couplings- Using a straight edge and a feeler gage to align shafts.- Align shafts using dial indicators.- Align shafts using precision alignment tools.
- Bearings and Seals - Identify and describe:- Plain bearings- Ball bearings- Roller bearings- Angular contact bearings- Associated seals
- Mechanical Drives - Perform V-belt sheave alignment and belt tensioning.
- Mechanical Drives - Install variable-speed belt drives.
- Mechanical Drives - Perform belt drive system identification and visual inspection
- Mechanical Drives - Identify and describe common types of belts used for flexible belt drives.
- Mechanical Drives - Perform pulley fit to shaft
- Mechanical Drives - Install set screws and keys
- Mechanical Drives - Properly install and tension timing belts.
- Mechanical Drives - Troubleshoot pulley wear
- Mechanical Drives - Perform belt or drive unit replacement
- Mechanical Drives - Perform run-out and balance of a pulley
- Mechanical Drives - Identify the various engineering chain types and drive chain sprockets
- Mechanical Drives - Identify and describe common types of chains used for flexible chain drives.
- Mechanical Drives - Check for excessive wear and run-out of the sprockets.
- Mechanical Drives - Perform sprocket fit to shaft.
- Mechanical Drives - Install roller chain drives and sprockets.
- Mechanical Drives - Perform chain and sprocket alignment and tension.
- Mechanical Drives - Install set screws and keys.
- Mechanical Drives - Perform chain or drive unit replacement.
- Mechanical Drives - Identify and describe silent chain drives.
- Mechanical Drives - Properly perform alignment and chain tension.
- Mechanical Drives - Install chain guards.
- Clutches and Brakes - Identify clutch and brake functions and uses.
- Clutches and Brakes - Identify mechanical-lockup interfaces and actuation methods.
- Clutches and Brakes - Install a clutch/brake assembly.
- Gear Drives - Identify and describe gear drive functions and uses.
- Gear Drives - Identify and describe associated seals, breathers, and lubrication.
- Gear Drives - Assemble - A parallel shaft gear drive. - A worm and wheel gearbox drive unit. - An angle shaft gear drive.
- Industrial Cams - Identify the common types of cam followers and rod ends
- Mechanical Drives - Inspect for sprocket wear.
- Clutches and Brakes - Identify friction and electromagnetic types of clutches.
- Clutches and Brakes - Perform clutch and brake identification and visual inspection.
- Gear Drives - Explain gear ratings and application.
- Industrial Cams - Identify industrial cam followers and functions
- Gear Drives - Identify and describe open gears and enclosed gears.
- Gear Drives - Recognize and explain gear identification.
- Industrial Cams - Identify industrial cam follower bushing types and operating clearances
- Industrial Cams - Replace, install, and adjust cam followers and rod ends
- Machine Tool
- Safety - Identify, explain, and demonstrate safe working practices while in any machining environment.
- Measurement Systems - Recognize and explain the difference between measurement accuracy and measurement precision.
- Manual and Power Machine Tool Use - Describe the operation of a drill press.
- Precision Layout - Identify and explain safe use and care of a surface plate.
- Precision Layout - Explain how to build a gauge block stack, and the process of wringing gague blocks.
- Band Saw Operations - Describe the operation of a horizontal band saw.
- Band Saw Operations - Set up and operate horizontal band saw, deburr safely and proficiently sawing various size mild steel to blue print specifications.
- Drill Press Operations - Set up and operate drill press safely and proficiently, layout, drill, ream, chamfer, and assemble completed details per blue print specifications.
- Lathe Operations - Identify ten safety rules to follow during operation of the lathe.
- Lathe Operations - Describe the function and operation of a universal three-jaw and independent four-jaw laithe chucks.
- Lathe Operations - Identify the two types of chamfer that can be created on the lathe.
- Mill Operations - Describe the function and operation of the micrometer collars for the two movements of the knee.
- Measurement Systems - Explain dimensional measurement and its importance.
- Measurement Systems - Perform basic and precision measurement using - A decimal-inch machinist’s rule. - A common fraction-inch rule - A zero to one inch micrometer. - A zero to 25 milimeter micrometer. - A six inch dial caliper. - A 150 mm dial caliper.
- Manual and Power Machine Tool Use - Set up and operate an engine lathe.
- Manual and Power Machine Tool Use - Set up and operate drill press.
- Manual and Power Machine Tool Use - Explain the function and operation of a bench vise.
- Precision Layout - Recognize bore gauges and explain their purpose.
- Precision Layout - Discuss an adjustable size bore gauge.
- Drill Press Operations - Identify and explain the purpose of various of cutting fluids.
- Lathe Operations - Recognize the function of two types of cuts performed on the lathe.
- Lathe Operations - Tell how to drill a hole on a lathe.
- Mill Operations - Discuss six safety rules to be followed before starting a milling operation.
- Mill Operations - Set up and operate milling machine safely and proficiently.
- Manual and Power Machine Tool Use - Demonstrate knowledge of standard machine tool movements.
- Measurement Systems - Review two systems of dimensional measurements: Define and explain the difference between U.S. Customary and Scientific International.
- Manual and Power Machine Tool Use - Describe the operation of a horizontal lathe.
- Manual and Power Machine Tool Use - Describe the operation of metal cutting saws.
- Manual and Power Machine Tool Use - Use hand and bench tools properly.
- Manual and Power Machine Tool Use - Describe the function and operation of a file.
- Precision Layout - Explain how to use a bore gauge.
- Precision Layout - Measure lengths, widths, diameters, of various gauge block builds, gauge pins, and also convert inch measurement to metric.
- Drill Press Operations - Describe the process of reaming, countersinking, counter boring, tapping, and chamfering.
- Lathe Operations - Explain the operation of a manual lathe.
- Lathe Operations - Set up and operate the lathe safely and proficiently, layout, face ends of journals to size, turn journals and chamfers to blue print specifications, drill, tap, and ream using the tailstock.
- Mill Operations - Explain how backlash affects the accuracy of a mill, and describe the difference between climb and down milling.
- Mill Operations - Identify a step and explain the two methods used to locate the tool position when milling a step.
- Measurement Systems - Demonstrate common conversions between U.S. customary system and the S.I. Metric system.
- Measurement Systems - Define and explain the purpose and function of a machinist’s rule.
- Manual and Power Machine Tool Use - Describe metal cutting processes and the production of shapes.
- Manual and Power Machine Tool Use - Describe the operation of a vertical milling machine.
- Manual and Power Machine Tool Use - Set up and operate horizontal and vertical band saws.
- Manual and Power Machine Tool Use - Use power tools properly.
- Manual and Power Machine Tool Use - Describe the function and operation of a hacksaw.
- Precision Layout - Define the purpose and use of a surface plate.
- Precision Layout - Perform basic and precision layout.
- Precision Layout - Explain the purpose of gauge blocks.
- Precision Layout - Layout and install per blue print specifications, power drill and hand tap holes then install chamfers using the belt sander and pencil grinder.
- Precision Layout - Given a component drawing, describe the process from rough cut to finished part (machine tools used, order of use, etc.).
- Band Saw Operations - Describe the operation of a vertical band saw.
- Drill Press Operations - Explain the operation of a floor drill press.
- Drill Press Operations - Describe the form and cutting action of twist drills.
- Lathe Operations - Identify six safety rules to follow before starting a lathe.
- Lathe Operations - Describe the function of three hand wheels used to feed the cutting tool.
- Lathe Operations - Explain the operation of the two types of micrometer collars on the cross feed.
- Lathe Operations - Explain the operation of automatic feed and describe the advantage.
- Lathe Operations - Describe groove tools, threading tools, combination drill and countersink bit.
- Mill Operations - Describe the operation of a vertical mill.
- Mill Operations - Explain the difference between a slot and a pocket.
- Instrumentation
- Convert PSIA readings to PSIG, inches of mercury, inches of water, Bars, and Atmospheres.
- Lean Manufacturing
- Principles of Lean - Identify the seven forms of waste and give an example of each.
- Principles of Lean - Identify the Challenges to be addressed when implementing lean.
- Principles of Lean - List several methods that can be demonstrated by management that reflects an understanding for the Respect for Humanity.
- Principles of Lean - Given an integrated system, identify all areas (stations) that reflect the principle of “Quality Built In” and list the additions that could be made in the integrated system to improve this principle.
- Principles of Lean - Identify when it is appropriate to use Continuous Improvement activities and give 2 examples of Continuous improvement associated with the student’s place of work.
- Principles of Lean - Identify the advantages to be realized by implementing lean.
- Principles of Lean - Identify the impact of Lean on the work force, the organization and the customer
- Tools of Lean - List two examples of visual Management that is being applied at the student’s plant.
- Tools of Lean - List the 5 “S”s and match to a list of activities that exemplifies each.
- Principles of Lean - List the characteristics of quality product.
- Tools of Lean - Define Kanban and identify the major functions associated with this tool. List an example of each function.
- Tools of Lean - Identify applications of visual controls that can be found in the plant environment.
- Tools of Lean - Demonstrate error and mistake proofing given a detailed description of a work cell and common operator error.
- Tools of Lean - Define a customer needs and expectations “PULL” enterprise.
- Roles - Identify the roles of the worker to support lean implementation
- Tools of Lean - Given a sample of standardized work, identify the strengths and weaknesses of the form.
- Continuous Improvement - When comparing typical mass production environments with a lean environment identify the differing characteristics of process Improvement, Quality, and daily operations of each.
- Tools of Lean - Define the “5 why” methodology.
- Continuous Improvement - Identify the elements and considerations associated with critical thinking.
- Tools of Lean - Define “Value Added.”
- Continuous Improvement - Given a case study, identify whether it illustrates leveled production or not.
- Continuous Improvement - Identify what a lean educational model would look like.
- Continuous Improvement - From the case study in objective 4, determine if it illustrates Just-In-Time Production and be able to defend you analysis in class room discussions.
- Predictive Maintenance
- Practice advanced predictive maintenance safety by: - Identifying common predictive maintenance safety guidelines - Identifying the potential hazard of pinch points - Explaining the proper procedure for lockout, tagout, and blockout
- Explain shaft alignment by: - Describing and demonstrating the basic concepts of shaft alignment
- Explain network analysis by being able to interpret the results and describe appropriate corrective actions.
- Preventive Maintenance
- Identify, Explain, and Demonstrate safe practices when doing general preventative maintenance including common slip hazards, hydraulic system injection hazards, and chemical hazards.
- After completing assigned work, ensure that the work area is left clean and free of debris, maintenance supplies, parts and tools.
- Using manufacturers' literature/recommendations or other typical plant resources, select the appropriate lubricant for a track.
- Perform equipment checks, including: - Perform visual Inspection of equipment - Check gagues
- Maintain oil and grease levels by doing the following: - Check sight glass-hydraulic oils - Check grease canisters - Check air lubricators - Check gear box oils
- Change air and oil filters as prescribed, and demonstrate the proper disposal of used filters.
- Monitor floor management development system by doing the following: - Maintain neat work area - Replace used tolls and equipment in designated areas - Establish minimum and maximum quantities acceptable for floor area
- ControlLogix
- Layout - Identify and give a use for each of the following layout work holding tools: a. Surface Plates b. Angle Blocks c. V-Blocks d. Parallels
- Layout - Demonstrate the use of each precision layout tool listed below and match each tool to its application: a. Height Gage b. Sine Bar c. Vernier Bevel Protractors
- Layout - List the general layout steps, and then physically layout, the necessary detail from a given print.
- Layout - Match which semi-precision and precision layout tools will be needed, when given sample layouts.
- Layout - Given a print, list the general layout steps, then physically layout the necessary detail.
- Layout - Identify each of the following and match the device to it's application: a. Layout Dye b. Scribers c. Divider d. Trammel e. Surface Gage f. Combination Set g. Center Head h. Prick Punch
- Layout - Identify the types of measurements that can be measured accurately with steel rules.
- Layout - List the different configurations of steel rules.
- Layout - Differentiate between a fractional and decimal scale and identify what scale needs to be used based on the dimensional size of the part print.
- Layout - Demonstrate the proper use of a steel rule and identify the types of measurements that can be measured accurately with them.
- Layout - Determine a measurement value using a fractional scale, and a decimal scale.
- Layout - Identify the different components of precision calipers.
- Layout - Physically layout selected jobs for parts to be machined.
- Layout - Demonstrate the proper use of an inch Vernier precision caliper.
- Layout - Demonstrate the proper use of a metric Vernier precision caliper.
- Layout - Demonstrate the proper use of a dial precision caliper.
- Layout - Identify the three different measurements that can be taken with precision calipers.
- Layout - Demonstrate how to clean and calibrate precision calipers.
- Layout - Demonstrate the proper use of a digital precision caliper.
- Layout - Identify and define the different components of vernier and dial micrometers.
- Layout - Identify specifications that should be measured with a precision calipers.
- Layout - Demonstrate how to properly handle and maintain micrometers.
- Layout - Demonstrate the proper use of a depth micrometers.
- Speeds and Feeds - Identify and use the turning RPM formula for spindle speed.
- Speeds and Feeds - Identify and use the turning IPR formula for feed rate.
- Speeds and Feeds - Identify and use the formula for converting IPM to IPR and vice versa.
- Layout - Demonstrate how to properly test and calibrate micrometers.
- Speeds and Feeds - Identify and use the milling RPM formula for spindle speed.
- Speeds and Feeds - Identify and use the drilling RPM formula for spindle speed.
- Layout - Demonstrate the proper use of an outside micrometers.
- Layout - Properly test and calibrate micrometers.
- Speeds and Feeds - Interpret a cutting tool vendor table.
- Speeds and Feeds - Identify and use the drilling IPM formula for feed rate.
- Speeds and Feeds - Identify and use the milling IPM formula for feed rate.
- Robotics
- Locate & identify all components of the robotic cell including all equipment, operator interfaces, tooling, perimeter guarding, safety devices, etc.
- Demonstrate the proper power-up and shut-down sequence of the robotic cell.
- Use the teach pendant to identify & clear alarms that would inhibit robotic cell operation. View alarm history. (Book procedure exercise)
- Perform the Cold Start procedure and describe the benefit. (Book procedure exercise)
- Identify & practice all safety considerations related to operating the robotic cell.
- Identify the proper names for the axis for both Joint and Cartesian coordinate systems as applicable to the robot. (Written)
- Reset and clear teach pendant errors. (Book procedure exercise)
- Navigate & match teach pendant screens to their proper name & function. (Hands-on with written exercise and book reference)
- Locate & identify the main components of the robot including the controller, manipulator arm, teach pendant, standard operator panel, dress-out, cables, connections, and end-of-arm-tooling or vacuum components.
- Jog the robot in each coordinate system and document the arm motion. (Hands-on with written exercise and book reference)
- Predict the movement of the robot when operating in the following coordinate system: Joint, World, Tool, User
- Repeatably demonstrate the ability to teach a robot out of a fixture with zero moves in the wrong direction.
- Adjust the robot jog speed. (Hands-on exercise with book reference)
- Match each teach pendant button to their proper name & function. (Hands-on with written exercise and book reference)
- Industrial Electricity
- Safely work with electricity and electrical components.
- Match a list of the fundamental ways of generating electricity with examples of each.
- Match a list of fuses and circuit breakers to their proper descriptions.
- Match the following list of electrical terms to their proper definition: - Volt - Ampere - Ohm - Conductance - Resistance - Insulator - Resistor - Open - Short - Coulomb
- Match wire samples to a list of their proper size and description.
- Match a list of safety practices to the electrical hazards they prevent.
- Identify the level of current that poses a serious life-threatening condition to the human body.
- Match standardized symbols used in schematic diagrams to their proper electronic components.
- Using live electrical circuits, make voltage measurements with respect to ground.
- Match a list of markings, single phase, and three phase wiring schemes (Wye, Delta) to their proper description.
- Match a list of the kinds of personal protection equipment to their proper description.
- Use a continuity checker and an ohmmeter to verify the normally open and normally closed set of contacts on a switch.
- Use a voltmeter to determine the state of a switch (open or closed) in a circuit under power. Additionally, predict and verify with an ammeter whether current is flowing.
- Pneumatics
- List the purpose, function, and features of the following miscellaneous pneumatic devices: - After coolers - Dryers - Receivers - Surge tanks - Accumulators - Compressors
- Convert readings in P.S.I.A. to the following units using text references: - Inches of mercury - Inches of water - PSIG - Bars - Atmospheres
- List the long term symptoms associated with a lack of preventive maintenance of the following: - Dryers - Lubricators - Filters - Air receivers - Coalescing filters - F-R-L
- Identify the possible danger associated with spring off-set directional control valves (when power is removed).
- Match the following components with a description of their function and their symbol: - Mufflers - Silencers - Filters - Lubricators - FRLs
- Teamwork and Leadership
- Teamwork - Demonstrate brainstorming in a meeting.
- Teamwork - Demonstrate the ability to handle conflicts in a team.
- Project Management - Given a description of a project, generate a Gantt chart.
- Project Management - Define knowledge management and give examples.
- Tools - Given a description of an organizational problem demonstrate critical thinking techniques to identify the cause of the problem.
- Tools - Given a description of a project management process problem demonstrate critical thinking techniques to identify the cause of the problem.
- Leadership - Demonstrate positive reinforcement methods and how this affects behavior-increases positive behaviors.
- Project Management - Given a description of a project, develop a Critical path diagram.
- Project Management - Given a description of a project, develop a management reporting tool to identify scope creep.
- Project Management - Identify methods of capturing lessons learned from a project that has been completed.
- Project Management - Identify methods of embedding lessons learned into a new project.
- Project Management - Demonstrate error and mistake proofing as it applies to project management.
- Tools - Demonstrate the understanding of error and mistake proofing as it applies to a manufacturing process
- Tools - Given a description of a manufacturing problem demonstrate critical thinking techniques to identify the cause of the problem.
- Leadership - Demonstrate ability to perform employee evaluations and performance reviews – giving constructive feedback to reinforce good behavior/performance.
- Project Management - Given a description of a project, develop a work breakdown structure.
- Project Management - Define “goal setting” and logical approach to project completion
- Leadership - Identify constructive techniques in dealing with the 5S
- Teamwork - Demonstrate the ability to mediate as a way to resolve “inter group” conflict.
- Project Management - Given a description of a project, identify items within and out of scope of the project.
- Project Management - Identify methods of successful implementation of a knowledge manage system.
- Leadership - Apply effective coaching techniques.
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