Spark erosion machine operator

Spark erosion machine operators set up and tend spark erosion machines designed to cut excess material from a metal workpiece by the use of electrical discharges, or sparks, caused by electric voltage and separated by a dielectric liquid, which removes pieces of metal from the electrodes These applications can involve transmission and optical microscopy.

The following job titles also refer to spark erosion machine operator:

electrical sealing machine operator
electrical discharge machine set up operator
electrical discharge machine setter
electrical sealing machine operative
electrical discharge machine operator
electrical discharge machine set up operative
electrical discharge machine setup operative
electrical discharge machine operative
electrical discharge machine set up technician
electrical discharge machine eroder
electrical discharge machine setup technician
electrical discharge machine setup operator

No formal educational credential is generally required to work as spark erosion machine operator. However, this requirement may differ in some countries.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Spark erosion machine operator is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to spark erosion machine operator.

plasma cutting machine operator
oxy fuel burning machine operator
boring machine operator
punch press operator
laser marking machine operator

These occupations require some skills and knowledge of spark erosion machine operator. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of spark erosion machine operator with a significant experience and/or extensive training.

automated assembly line operator
metal production supervisor
pulp control operator
container equipment assembly supervisor
automation engineering technician

This knowledge should be acquired through learning to fulfill the role of spark erosion machine operator.

Electrical discharge: Tthe qualities and applications of electrical discharge, including voltage and electrodes.
Types of metal: Qualities, specifications, applications and reactions to different fabricating processes of various types of metal, such as steel, aluminium, brass, copper and others.
Quality standards: The national and international requirements, specifications and guidelines to ensure that products, services and processes are of good quality and fit for purpose.
Metal eroding technology: The various eroding technology and techniques, automated or otherwise, such as electrical discharge machining, die sinking, wire eroding and others.

These skills are necessary for the role of spark erosion machine operator.

Remove inadequate workpieces: Evaluate which deficient processed workpieces do not meet the set-up standard and should be removed and sort the waste according to regulations.
Troubleshoot: Identify operating problems, decide what to do about it and report accordingly.
Tend spark erosion machine: Monitor and operate a spark erosion machine according to regulations.
Remove processed workpiece: Remove individual workpieces after processing, from the manufacturing machine or the machine tool. In case of a conveyor belt this involves quick, continuous movement.
Operate precision measuring equipment: Measure the size of a processed part when checking and marking it to check if it is up to standard by use of two and three dimensional precision measuring equipment such as a caliper, a micrometer, and a measuring gauge.
Dispose of cutting waste material: Dispose of possibly hazardous waste material created in the cutting process, such as swarf, scrap and slugs, sort according to regulations, and clean up workplace.
Apply cross-reference tools for product identification: Employ cross-reference tools and programmes, listing file names and line numbers, to identify part numbers, descriptions, and the vendor as source of origin.
Monitor automated machines: Continuously check up on the automated machine’s set-up and execution or make regular control rounds. If necessary, record and interpret data on the operating conditions of installations and equipment in order to identify abnormalities.
Supply machine: Ensure the machine is fed the necessary and adequate materials and control the placement or automatic feed and retrieval of work pieces in the machines or machine tools on the production line.
Consult technical resources: Read and interpret such technical resources such as digital or paper drawings and adjustment data in order to properly set up a machine or working tool, or to assemble mechanical equipment.
Set up the controller of a machine: Set up and give commands to a machine by dispatching the appropriate data and input into the (computer) controller corresponding with the desired processed product.

This knowledge is sometimes, but not always, required for the role of spark erosion machine operator. However, mastering this knowledge allows you to have more opportunities for career development.

Non-ferrous metal processing: Various processing methods on non-ferrous metals and alloys such as copper, zinc and aluminium.
Statistical process control: Method of quality control that uses statistics to monitor processes.
Cutting technologies: The variety of cutting technologies, such as software or mechanics, guiding cutting processes through lasering, sawing, milling etc.
Manufacturing of cutlery: The manufacture of different cutlery items, such as forks, spoons, knives, razors or scissors.
Quality and cycle time optimisation: The most optimal rotation or cycle time and over-all quality of a tool or a machine’s processes.
Electrical engineering: Understand electrical engineering, a field of engineering that deals with the study and application of electricity, electronics, and electromagnetism.
Ferrous metal processing: Various processing methods on iron and iron-containing alloys such as steel, stainless steel and pig iron.
Manufacturing of metal household articles: The manufacture of flatware , hollowware , dinnerware and other non-electrical utensils for use at the table or in the kitchen.
Manufacturing of small metal parts: The manufacture of metal cable, plaited bands and other articles of that typr, uninsulated or insulated cable not capable of being used as a conductor of electricity, coated or cored wire as well as barbed wire, wire fencing, grill, netting, cloth etc. Manufacture of coated electrodes for electric arc-welding, nails and pins, chain and springs (except watch springs): as well as leaves for springs.
Manufacturing of metal containers: The manufacture of reservoirs, tanks and similar containers of metal, of types normally installed as fixtures for storage or manufacturing use. The manufacture of metal containers for compressed or liquefied gas.
Types of metal manufacturing processes: Metal processes linked to the different types of metal, such as casting processes, heat treatment processes, repair processes and other metal manufacturing processes.
Manufacturing of door furniture from metal: The manufacture of metal items that can be attached to a door in order to support its function and appearance. The manufacture of padlocks, locks, keys, hinges and the like, and hardware for buildings, furniture, vehicles etc.
Manufacturing of light metal packaging: The manufacture of tins and cans for food products, collapsible tubes and boxes, and of metallic closures.
Chemistry: The composition, structure, and properties of substances and the processes and transformations that they undergo; the uses of different chemicals and their interactions, production techniques, risk factors, and disposal methods.
Manufacturing of weapons and ammunition: The manufacture of heavy weapons (artillery, mobile guns, rocket launchers, torpedo tubes, heavy machine guns), small arms (revolvers, shotguns, light machine guns), air or gas guns and pistols, and war ammunition. Also the manufacture of hunting, sporting or protective firearms and ammunition and of explosive devices such as bombs, mines and torpedoes.
Manufacturing of tools: The manufacture of knives and cutting blades for machines or for mechanical appliances, hand tools such as pliers, screwdrivers etc. The manufacture of non-power-driven agricultural hand tools, saws and saw blades, including circular saw blades and chainsaw blades. The manufacture of interchangeable tools for hand tools, whether or not power-operated, or for machine tools: drills, punches, milling cutters etc. The manufacture of press tools, moulding boxes and moulds (except ingot moulds), vices and clamps, and blacksmiths’ tools: forges, anvils etc.
Manufacturing of steam generators: The manufacture of steam or other vapour generators, the manufacture of auxiliary plant for use with steam generators: condensers, economisers, superheaters, steam collectors and accumulators. The manufacture of nuclear reactors, parts for marine or power boilers. Also the production of pipe system construction comprising further processing of tubes generally to make pressure pipes or pipe systems together with the associated design and construction work.

These skills and competences are sometimes, but not always, required for the role of spark erosion machine operator. However, mastering these skills and competences allows you to have more opportunities for career development.

Inspect quality of products: Use various techniques to ensure the product quality is respecting the quality standards and specifications. Oversee defects, packaging and sendbacks of products to different production departments.
Record production data for quality control: Keep records of the machine’s faults, interventions and irregularities for quality control.
Perform product testing: Test processed workpieces or products for basic faults.
Monitor stock level: Evaluate how much stock is used and determine what should be ordered.
Perform test run: Perform tests putting a system, machine, tool or other equipment through a series of actions under actual operating conditions in order to assess its reliability and suitability to realise its tasks, and adjust settings accordingly.
Ensure public safety and security: Implement the relevant procedures, strategies and use the proper equipment to promote local or national security activities for the protection of data, people, institutions, and property.
Read standard blueprints: Read and comprehend standard blueprints, machine, and process drawings.
Ensure equipment availability: Ensure that the necessary equipment is provided, ready and available for use before start of procedures.
Use cam software: Use computer-aided manufacturing (CAM) programmes to control machinery and machine tools in the creation, modification, analysis, or optimisation as part of the manufacturing processes of workpieces.
Provide advice to technicians: Offer help and advice to service technicians in case of machine malfunctions and other repair tasks.
Mark processed workpiece: Inspect and mark parts of the workpiece to indicate how they will fit into the finished product.
Maintain mechanical equipment: Observe and listen to machinery operation to detect malfunction. Service, repair, adjust, and test machines, parts, and equipment that operate primarily on the basis of mechanical principles. Maintain and repair vehicles meant for cargo, passengers, farming and landscaping.
Program a cnc controller: Set up the desired product design in the CNC controller of the CNC machine for product manufacturing.
Replace machines: Evaluate when to invest in replacing machines or machine tools and take the necessary actions.
Keep records of work progress: Maintain records of the progress of the work including time, defects, malfunctions, etc.
Interpret geometric dimensions and tolerances: Understand and assess the models and symbolic language of the GD&T system indicating engineering tolerances.
Apply control process statistical methods: Apply statistical methods from Design of Experiments (DOE) and Statistical Process Control (SPC) in order to control manufacturing processes.

7223 – Metal working machine tool setters and operators

References

1. Spark erosion machine operator – ESCO