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DACUM Research Chart for Precision Machinist

DACUM Panel Sponsored by Michael Blanchard Machinist Hampton Roads Sanitation District Virginia Beach, VA

Chris Chapman Project Manager Colonna’s Shipyard/ America Norfolk, VA

Donnie Corn Machine Shop Manager Electric Motor and Contracting Co. Inc. Jim Wiseman Chesapeake, VA Inside Machine Shop Superintendent Auxiliary Systems, Inc. Thomas Kuehne Norfolk, VA Apprenticeship Program Coordinator Stihl, Inc. Michael Wozniel Virginia Beach, VA Plant Manager Sumitomo Drive Tech John R. Lowe Chesapeake, VA Apprenticeship Instructor Norfolk Naval Shipyard Portsmouth, VA DACUM Facilitators

Jody S. McClintock Cindy Cadieux Production Manager Neil Collins Earl Industries, LLC-Precision Mfg. Dept. Jimmy Peterson Portsmouth, VA John Moser, Team Leader

Rick Merkle Recruitment & Apprenticeship Coordinator Earl Industries, LLC-Human Resources Produced by Portsmouth, VA

Rick Raike Chief of Facility Support Hampton Roads Sanitation District Virginia Beach, VA

Derek A. Taylor 1900 Kenny Road Master Tradesman 1 Columbus, OH 43210 AMSEC Hampton, VA April 19-20, 2012

DACUM Research Chart for Precision Machinist

Duties Tasks Review A-1 Review A-2 Review A-3 A-4 Identify special A-5 Identify A Job work order blueprint/ Clarify job processes (e.g., machine(s) to Process drawing require- plating, coating, use ments heat-treating) Develop B-1 Identify B-2 Obtain B-3 Fabricate B-4 Determine B-5 Determine B machine machine special tools feed & speed rough part Processes sequence (e.g., tooling for machining dimensions lathe, drillpress) operations Obtain C-1 Identify C-2 Complete C-3 Transport C-4 Receipt- C-5 Layout C Raw raw material raw material raw material to inspect raw raw material Materials type & size requisition site material

Perform D-1 Layout D-2 Build D-3 Install work- D-4 Secure D-5 Verify D Job part profile work- holding device raw material calibration of Setup holding (e.g., , vice, into work- measuring fixtures ) holding device tools Manufacture E-1 Position E-2 Establish E-3 Determine E-4 Set cut E-5 Rough E Machine cutting tool reference material to depth part IAW Parts* points/datum remove machining processes E-13 Prepare E-14 technical Participate in reports shop-specific training Perform F-1 Machine F-2 Machine F-3 Center F-4 Turn F-5 holes F Lathe part face part drill machine ID/OD (e.g., in parts Operations parts length, taper, threads) F-13 Perform F-14 Perform part or parting operations

Perform G-1 Perform G-2 Perform G-3 Machine G-4 Machine G-5 G Machine fly cut/milling operation counter bore/ part angles (e.g., Perform Operations operation (e.g., bolt circles, taper, bevels, index hole pattern) ) milling Perform Surface H-1 Ring test H-2 Balance H-3 Install H-4 Dress H-5 Perform H Grinder grinding wheel grinding wheel grinding grinding operation Operation wheel (e.g., topsurface, grooves, radius) Perform I-1 Select saw I-2 Cut & I-3 Mount saw I-4 Break in I-5 Cut parts I Sawing blade (e.g., weld saw blade blade (e.g., set saw blade profile (e.g., Operations pitch, rake, guides, set miter, angles, thickness) tensions) radius) Perform J-1 Select drill J-2 Sharpen J-3 Center J-4 Set drill J-5 Select tool J Drill Press press tooling drill part depths bit rotation Operations

*Tasks in this duty apply to the lathe, milling machine, surface grinder, saw, and drill press.

April 19-20, 2012

A-6 Identify machine tooling

C-6 Saw raw C-7 Mark C-8 Restock material excess raw excess raw material material

D-6 Verify D-7 Indicate D-8 Set up D-9 Top off D-10 Set D-11 Set up calibration of (align) stock cutting tools cutting fluids machine machine guard equipment materials into machine controls (e.g., feed, speed) E-6 Adjust E-7 Take in- E-8 E-9 Perform E-10 Deburr E-11 Polish E-12 Verify feed & speeds process Troubleshoot finishing finished part finished part finished parts measurements machine operations (e.g., dimension, tooling issues features)

F-6 Machine F-7 Perform F-8 Machine F-9 Perform F-10 Cut F-11 Grind F-12 Burnish part groves knurling phonographic tapping ways part profiles part profiles (e.g., ID, OD, operation finish operation faces)

G-6 Perform milling G-7 Perform pocket G-8 Perform machine finishing milling (e.g., holes, operation (e.g., tapping, slots, circles, groves) operation burnishing, reaming)

Acronyms

IAW In Accordance With ID/OD Inside Diameter/Outside Diameter MSDS Material Safety Data Sheets OEM Original Equipment Manufacturer OSHA Occupational Safety & Health Administration J-6 Perform drilling J-7 Perform drill press PM Preventative Maintenance operations (e.g., tap, finishing operations PPE Personal Protective Equipment bore, ream, counter (e.g., chamfering, spot QA Quality Assurance bore/sink) , honing) TIR Total Indicator Runout

Duties Tasks Perform K-1 Perform K-2 Perform K-3 Perform layout K-4 Perform K Bench filing operations hand grinding operations (e.g., scribe lapping operations Work (e.g., thread, flat, operations (e.g., lines, arcs, bolt circles) round) disc, orbital, belt) K-5 Perform K-6 Perform K-7 Hand hand drilling hand tapping grind tool bits operations operations

Perform L-1 Perform L-2 Perform L-3 Perform L-4 Perform L-5 Perform L Precision thread surface finish height angular gear Measurements measurements measurements measurements measurements measurements

L-6 Perform L-7 Perform L-8 Perform L-9 Perform inside outside material runout dimension dimension hardness test measurements measurements measurements Maintain M-1 Perform M-2 Inspect M-3 Perform M-4 M-5 Maintain M Shop equipment PM hand tools equipment Maintain equipment fluid Equipment (e.g., daily, calibration equipment levels (e.g., monthly) cleanliness hydraulic, coolant) M-6 Perform M-7 Inspect lockout/tagout equipment procedures guards

General Knowledge and Skills Worker Behaviors

Knowledge of tooling geometry Communication skills Persistent Mature Time management skills Troubleshooting skills Knowledgeable Dependable Decision making skills Interpersonal skills Creative Punctual Learning skills Problem solving skills Team Player Ambitious Fabrication skills Blueprint reading skills Good listener Organized Drafting skills Organizational skills Able to compromise Good listener Knowledge of part handling Mechanical knowledge Open-minded Sense of humor techniques Precision measuring skills Attentive Self-starter Knowledge of special processes (e.g. Analytical skills Consistent Patient plating, heat treating, coating) Computer knowledge Positive Able to handle stress Regulatory knowledge (OSHA, EPA) Knowledge of tooling materials Honest Team player Knowledge of shop rules Metallurgical knowledge Trustworthy Adaptable Knowledge of machine safety Knowledge of trade theory Able to follow Healthy Basic math knowledge Technical writing skills directions Loyal MSDS knowledge Knowledge of grinding wheels Detail-oriented Willing to help others Machine-specific knowledge Knowledge of work holding Safety-oriented Material knowledge devices Knowledge of cutting tools Knowledge of hand tool usage

DACUM Research Chart for Precision Machinist

Tools, Equipment, Supplies and Materials Future Trends and Concerns

Laptop/computer Heat treat oven Perception of the trade unchanged PPE Hardness tester Competitive wages Mobile phone Extractors Good job security Machinery’s Handbook Profilometer Improved working conditions Microsoft Office software Refractormeter Industry competition Equipment-specific technical manuals Gauge blocks Foreign competition Scientific calculator Pin gauges Struggling economy Emory cloth Thread pitch gauges Growing material/product costs Shop rags/gloves Radius gauges Lack of skilled trades candidates Drill bits Broom Regulatory challenges Parting tool Coal shovel Cost of energy Carbide inserts Pedestal grinder Infrastructure Knurling tool Horizontal lathe Succession planning Taps & dies Key seater Nano technology Rollaround toolbox Vertical mill Shop press Hand tools (e.g. Allen wrenches, Magnetic drill rubber mallet, ball peen hammer) Vertical turret lathe Counter bore/sink Horizontal boring mill Measuring tools: Blanchard grinder Broach Indicator Metal brake Tape measure Band saw Vernier Shim stock Depth micrometers Files Protractors Rubber mat Precision squares Sand blaster Combination squares Digital readouts Angle finder Oxyacetylene torches Steel scales Flashlight