Training Plan: CNC Machinist – Ceramic Materials
Note: Some of the training will take place concurrently, not sequentially. Training will be conducted by
engineering and technician staff. Training will be overseen by
PHASE I
Observe Co-Workers Machining
Tasks:
1) Shadow engineer doing ceramics machining (milling, grinding, drilling, turning, etc.) operations on all
machines.
2) Orientation to tooling, materials, machines and inspection tools used to manufacture various parts.
3) Introduction to CNC program documentation.
Competency: Become familiar with Shop layout, duties of job, machine operation and tooling that is used
to fabricate different ceramic material components.
Time/Hours: 80 hours
Identify and Understand Controls of CNC Machine for Ceramic Fabrication
Tasks:
1) Learn to identify and understand the CNC machine center interface to control the machine tool in manual
mode through shadowing, reading the instruction manual and practice.
2) Learn to adjust CNC machine center feed, speeds and tool change sequence.
3) Learn to mount tools into CNC machine compatible tool holders.
4) Learn to insert and remove tool holder into/from CNC vertical spindle milling center.
Competency:
Develop understanding to operate CNC machine tool manually.
Time/Hours: 80 hours
Identify and Understand Controls of Manual Machines in Machine Group
Tasks:
1) Review types of manual machining conducted at ABC COMPANY. Learn to identify and understand the
manual machine control interfaces (surface grinder, milling and turning machines) used in the
manufacturing cell through shadowing, instruction and practice. Review specific machining procedures
and requirements for ceramic materials.
2) Learn to mount tools into machine-compatible tool holders.
3) Learn to change tooling for specific operations.
Competency: Set up, adjust and operate all the basic manual machine tools to perform precision operations for
ceramic part fabrication.
Time/Hours: 40 hours
Program Loading Into CNC System
Task:
Trainee will develop a basic understanding of the operating package and NC program to run machine through
shadowing, experiential learning and instruction. Program loading into the CNC machine is performed by
floppy disc or serial communication to network.
Competency:
Enter computer commands to store, retrieve and start programs.
Time/Hours: 20 hours
Operation of a Machine Tool Loading, Fixture Setup and Parts Loading/Unloading
Task:
Trainee will shadow and be instructed regarding raw materials used to make particular parts and how to
safely and successfully load materials into fixtures or work holders. Example of learning includes:
a)
b)
c)
d)
Mounting and demounting of fixtures
Loading and unloading ceramic raw materials on machine tools
Changing tool holders on both lathes and milling machines
Setting and adjusting for tooling offsets in the NC controls of the machine tool
Competency: Align and secure holding fixtures, cutting tools, attachments and materials onto machine.
Develop understanding of the proper set-up of machine tools.
Time/Hours: 120 hours
Basic Set-up of Machine
Tasks:
1) Through shadowing and hands on experience, Trainee will learn to change jaws in lathe (unique for every
product manufactured).
2) Load and clamp holding devices.
3) Change fixture on the milling machine and indicate to correct reference.
4) Inspect and change dull inserts (parts that cut metal) or other rotary cutting tools.
Competency:
Ability to set-up machine and identify and change-out worn, broken or dull tools.
Time/Hours: 40 hours
Documentation and Part Counts
Tasks:
1) Learn the importance of proper documentation and attention to detail when recording counts or variable
dimensions.
2) Through instruction and example trainee will be shown the necessary steps and sequence for all
documentation packages.
3) Trainee will be shown how to match revision levels with all documents to include: router, print, process
drawings, program and other pertinent documents.
Competency: Ability to correctly fill out the proper paperwork and verify revision level for all required
paperwork.
Time/Hours: 40 hours
Labor Vouchering, Time and Hour Logging
Tasks:
1) Trainee will learn the proper method for vouchering labor on time sheets.
2) Learn the different labor codes and aspects of government program time recording.
3) Learn how to properly log quantities completed or scrapped out into computer system.
4) Learn how to fill out manual correction slip in case of data entry error.
Competency: Ability to accurately identify and record part counts to specific projects, including blanks, scrap
and good fabricated parts. Ability to voucher against the correct labor codes based on activity.
Time/Hours: 20 hours
Shop Safety/Preventative Maintenance
Task:
Trainee will learn shop safety and preventative maintenance practices to include:
a) Safe lifting for back safety
b) Use of fork truck
c) Lock out tag out
d) Understanding Right to Know and MSDS (material safety data sheet)
e) Learn basic preventative maintenance and daily checks for machine tools
f) Shop cleanliness and organization
Competency: Ability to perform all duties in a safe and prescribed manner. Demonstrate knowledge of safe
handling of shop chemicals and supplies and preventative maintenance for machine tools.
Time/Hours: 20 hours
PHASE II
Learn to Verify Operations Package for Part Fabrication
Tasks:
1) Trainee will shadow and be instructed on the documents that the engineering group creates and issues for
part fabrication. A series of documents describing the operations used to manufacture parts to specific
engineering specifications include:
a) Blueprints
b)
c)
d)
e)
Actual set-up sheets including process steps
Tools and holding fixtures used to manufacture the part
The NC (numerical controlled) program printout
Process sheet and other pertinent documents that will differ based on the operation to be performed
2) Learn to ID tools required and place in machine.
3) Compare computer program printout with original part specifications to verify accuracy of program.
Competency: Determine sequence of machine operations and verify operations package with the part drawing
and ensure package is complete and at the same revision level.
Time/Hours: 100 hours
Read and Understand Basic Machine Code
Tasks:
1) Trainee learns about CNC machine code by shadowing, practice and studying what engineers have
programmed into the machine. Learn numbers and letters that define the control of the machine tools.
2) Modify existing programs for location changes, tool wear, speeds and other problems encountered during
operation and save modified programs.
Competency: Develop basic understanding of M&G code.
Time/Hours: 80 hours
Read Engineering Drawings
Task:
Learn through instruction, reading and practice to understand the information outlined in the title block of
engineering drawings including: drawing number and revision level of drawing, material(s) used to make part,
tolerance allowed for part, and form/shape to understand dimensions of part, both linear and circular.
Competency:
Be able to comprehend blueprints.
Time/Hours: 40 hours
Follow Documentation and Sequence of Operations
Tasks:
1) Develop an understanding of instructions and the practical application of engineering science and
technology.
2) Learn by instruction, experiential learning and reading manuals to set up machines from engineering
process sheets and drawings.
3) Develop a high level of attention to detail and understanding of the proper sequence of activities needed to
successfully manufacture a quality product.
Competency: Ability to successfully follow detailed instructions in the proper sequence.
Time/Hours: 40 hours
Quality Control Principles
Tasks:
1) Trainee will learn through shadowing and practice to make part(s) within engineering specifications as laid
out on blueprints.
2) Learn to measure, examine and inspect completed units to detect defects and ensure conformance to
specifications.
3) Learn to use inspection tools to validate the features created on the part(s) including inside micrometers,
outside micrometers, venier calipers, pin gauges, thread gages and indicators and optical microscopy.
4) Learn how to determine allowable tolerances from blue prints.
5) Learn which inspection tools to use for each characteristic based on tool accuracy and capability.
Competency: Ability to understand and apply quality control tolerances and principles.
Time/Hours: 80 hours
SOPS/Standard Work Instructions
Task:
Trainee will be trained through instruction and example to read and understand all shop documentation to
include SOPs, work instructions, quality control procedures and machine manuals.
Competency: Ability to thoroughly understand and explain all shop documentation.
Time/Hours: 40
Ceramics Material Identification and Handling
Tasks:
1) Trainee will be trained through discussion with engineers and technicians to identify various ceramic
materials used in construction of fuel cells.
2) Review handling procedures to prevent breakage, contamination or other problems.
Competency: Ability to identify different ceramics and explain handling procedures.
Time/Hours: 40
Ceramic Material Properties
Tasks:
1) Learn the basic difference between ceramic materials, metals and plastics.
2) Understand the properties of the different ceramics in order to assist in the fabrication operations.
Competency:
Ability to explain fundamental material characteristics of ceramics.
Time/Hours: 40
Ceramic Material Grinding Process
Tasks:
1) Review the differences between cutting, turning and grinding in terms of tooling, speeds, feeds and chip
formation.
2) Review the various tooling normally used for machining (grinding) ceramics and the sources to purchase.
3) Understand the relation of grinding force to material damage either visual or not.
Competency:
Recognize the safe region for grinding ceramic components to prevent material damage.
Time/Hours: 80 hrs.