The primary responsibility of this job will be rework grinding, with the expectation of performing Visual/Dimensional Inspection as directed.

MISSION:

To identify and correct visual / dimensional flaws in castings to insure the final product meets customer specifications. Based on business needs, may be required to perform the functions of visual / dimensional inspection, straightening, and CMM evaluation/disposition (along with their associated tasks i.e. hardness testing, UTT, targeting, etc.) as defined on PCC Technique Cards, blueprints and other documentation/work instructions.

NOTE:

The aim of this description is to recognize multi-skilled work which facilitates the flow of parts. Instead the multiple tasks are performed on the parts by a single employee. Each employee is expected to apply an average of 20 percent of their total hours worked, performing on one or more secondary functions in addition to a primary “core” function.

Examples:

1. If your primary “core function” is visual dimensional inspection, then the secondary function of straightening and/or CMM evaluation/disposition must be performed a minimum of 20 of the time.
2. If your primary “core function” is straightening, then the secondary function of visual dimensional inspection and/or CMM evaluation/disposition must be performed a minimum of 20 of the time.

PRINCIPAL ACCOUNTABILITIES:

1. Grinding

Objective: to review inspection paperwork, and grind and blend defect areas on castings; to blend welds to blueprint tolerances.

Essential Job Functions:

1. Reviews x-ray/inspection paperwork, sketches and blueprints to determine grinding requirements.
2. Removes surface and blind cavity defects from castings using rotary files, burrs, abrasives or belts to prepare castings for repair.
3. Blends and reworks repaired areas to specified tolerances; may use hand-held sandblaster.

1. Visual / Dimensional Inspection

Objective: to visually and dimensionally inspect castings in accordance with customer specifications and to ensure that only necessary rework is performed.

Essential Job Functions:

1. Follows Quality Systems and Technique Card requirements.
2. Fixtures some parts and leaves others freestanding.
3. Visually inspects castings as required.
4. Dimensionally inspects castings for conformance to blueprint and Technique Card specifications using templates, micrometers, fixtures, gauges, calipers, ultrasound, boroscope and other dimensional measuring devices.
5. Checks casting hardness using Brinell, Rockwell and other instruments.
6. Marks castings to identify area needing rework, mill rates, etc. in order to meet dimensional and visual specifications.
7. Adjusts fixtures, gauges and precision measuring tools to calibrated standards.

1. Straightening

Objective: to straighten castings to meet dimensional tolerances and customer specifications.

Essential Job Functions:

1. Sets up castings on surface plates or fixtures.
2. Evaluates the condition of parts using precision measuring toolsto determines the most effective method of straightening castings.
3. Establishes datums to casting surfaces and fixtures on surface plates straightens to a rotational tolerance.
4. Straightens casting to the required configuration using a variety of tools and devices, including presses, straightening fixtures, profile templates, and power or manual tools.

1. CMM Evaluation/Disposition

Objective: to review CMM Reports and determine using Technique Card Hit Maps and customer specifications if castings are in accordance with customer specifications and to ensure that only necessary rework is performed

Essential Job Functions:

1. Reviews CMM Reports for discrepancies.
2. Evaluate the CMM BT (Before Target) report and utilizing Localized Alignment. Values (LAV) establish rest point values for targeting.
3. Determine if discrepancies are acceptable to customer specification and/or applicable part specific requirements.
4. Evaluate discrepant part/s using standard Visual/Dimensional Inspection techniques to determine necessary rework to reprocess part/s back to customer specification.
5. Marks castings to identify area/s needing rework in order to meet specifications.

Routes discrepant part/s to the Rework Analyst for reprocessing.

1. Casting Repair and Analysis

1. Make recommendations to resolve part non-conformity. May work in other disciplines to resolve quality issues.
2. Performs other tasks as directed including blending of defect areas.
3. Makes recommendation for part routing as required.

1. Documentation

1. Completes and maintains a variety of records, logs and non-conformance reports and production reports as required.

1. Safety

Objective: to take responsibility for and demonstrate safe work practices.

1. Adheres to plant and department safety rules.
2. Safely operates all equipment and tools.
3. Identifies and reports safety problems.

1. Performs other duties as assigned.

EQUIPMENT, VEHICLES, TOOLS AND/OR MACHINERY USED:

1. Hoist
2. Pallet jacks
3. Dimensional measuring tools (e.g. calipers, micrometers, gauges)
4. Templates
5. Basic hand tools (hammers, wrenches, etc.)
6. Fabricated blocks
7. Hand grinders
8. Porta-power (hydraulic ram)
9. Band saws
10. Light meter
11. Fixtures
12. Surface plates
13. Protective equipment/clothing
14. Profilometer
15. Straightening Presses

TRAINING:

Training will be a combination of class work and on-the-job and in most cases accompanied with task specific training modules. It will be the employee’s responsibility to progress through these tasks with performance and quality levels that comply with the requirements identified in the Step Progression Record.

QUALIFICATIONS:

1. Current valid certification required in visual / dimensional inspection and UTT inspection. Some business operations may require rework analyst certification.
2. Previous training and/or experience in one or more of the following areas is preferred: straightening, targeting, grinding or CMM disposition.
3. Ability to perform mathematical calculations as required.
4. Ability to communicate effectively both verbally and in writing.
5. Ability to read, follow and interpret blueprints is required.
6. Ability to read and follow complex instructions on Technique Cards, Process Control Procedures and other technical specifications.
7. Ability to work independently and as a team member, and to give and receive instructions and training.
8. Physical ability to perform the essential job functions with or without reasonable accommodation.
9. Preference may be given to applicants who hold Rework Analyst Certification