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Maintenance Machinist Training

Working knowledge and use of common toolroom equipment to manufacture and repair components for in-house maintenance purposes.

prerequisites: maintenance fundamentals
potential career paths: none

Below is a list of the online classes and offline tasks included within the competency Maintenance Machinist.

Adhesives

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	Class	Offline Task
1.	Intro to Adhesive Bonding 110 This class describes adhesive bonding, adhesive classification, and the various factors that lead to a successful adhesive bond.	Locate common adhesives used within the facility; list surface materials appropriate for each adhesive.
2.	Intro to Adhesive Properties 130 This class describes the mechanical and nonmechanical properties of adhesives and addresses how they impact adhesive bonding.	Find the cure time and required surface prep for each common adhesive used in the work environment.
3.	Types of Adhesives 140 This class describes the characteristics, pros and cons, and applications of types of synthetic adhesives.	Recommend two new applications on the job where it is advantageous to substitute the use of an adhesive.

CNC

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	Class	Offline Task
1.	Mechanics of CNC 110 This class describes the mechanical systems involved in CNC axis movement, as well as how feedback is used for tool location.	Identify the servos and power sources on each CNC machine used on the job.
2.	Basics of the CNC Turning Center 120 This class describes the basic components of the turning center as well as the devices used on this machine. Includes an Interactive Lab.	Clamp and unclamp tooling in the lathe's turret with repeatable results.
3.	Basics of the CNC Machining Center 130 This class describes the basic components of the machining center as well as the devices used on this machine. Includes an Interactive Lab.	Assign tool numbers, and load and unload tooling in the mill's toolchanger according to company policy.
4.	Basics of the CNC Swiss-Type Lathe 135 This class describes the basic components of the Swiss-type lathe, as well as common tooling and machining operations.	Scan a common swiss-type lathe and point out basic components and power systems.
5.	CNC Coordinates 140 This class explains the arrangement and orientation of the basic axes on a common CNC lathe and both a vertical and horizontal CNC mill. Includes an Interactive Lab.	Home the machine and jog the turret or spindle along all machine axes.

Electrical Systems

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	Class	Offline Task
1.	Electrical Units 110 This class describes how electricity flows and explains the basic units used to measure electricity.	For equipment used in the work space, find the current, voltage, and resistance requirements for each piece of equipment.
2.	Safety for Electric Work 115 This class describes the safety risks associated with electricity. It also discusses the necessary precautions for working with electricity safely. *Includes an Interactive Lab.*	Starting with a fully powered machine, choose the appropriate PPE and follow all necessary procedures to replace a fuse and/or plug-in relay.

Fasteners

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	Class	Offline Task
1.	Intro to Fastener Threads 110 This class describes fastener threads and their characteristics, as well as explains different thread standards and classifications. Includes an Interactive Lab.	For a sample of different bolts, determine whether the bolt is English or metric and measure the threads per inch.
2.	Tools for Threaded Fasteners 120 This class outlines the different types of tools for assembly commonly used with threaded fasteners.	Demonstrate the safe and effective use of an open wrench, box wrench, hex key, and socket wrench.
3.	Overview of Non-Threaded Fasteners 125 This class summarizes the various types of non-threaded fasteners used in assemblies and describes their common applications.	Remove a gear held in place with a keyway and key slot; reinstall the gear.

Hydraulics and Pneumatics

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	Class	Offline Task
1.	Safety for Hydraulics and Pneumatics 105 This class addresses safe work practices for hydraulics and pneumatics and includes information on preventive measures for safety hazards in the manufacturing workplace.Includes an Interactive Lab.	Demonstrate the safe and complete release of energy from all hydraulic systems used on a machine; demonstrate the safe and complete release of energy from all pneumatic systems used on the machine.
2.	Intro to Hydraulic Components 120 This class presents an overview of basic hydraulic system components. Includes an Interactive Lab.	Using the appropriate resources, find a replacement valve, pump, and actuator for a specific hydraulic system.
3.	Intro to Pneumatic Components 125 This class presents an overview of basic pneumatic system components.	Using the appropriate resources, find a replacement valve, compressor, and actuator for a specific pneumatic system.
4.	Fittings for Fluid Systems 135 This class provides an overview of fittings for fluid power systems, including pipe fittings, tube fittings, hose fittings, and the seals that make them work.	Using the appropriate resources, find replacement fittings for the fluid system on a specific machine; install a new fitting.
5.	Preventive Maintenance for Fluid Systems 140 This class provides an introduction to preventive maintenance for hydraulic and pneumatic fluid systems.	Read through the maintenance schedules for three common machines used in the work environment; demonstrate how to perform the fluid-system-related daily, weekly, and montly tasks.

Manual Machining

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	Class	Offline Task
1.	Basics of the Manual Mill 110 This class describes the basic components of the manual mill and also describes common workholding devices, cutting tools, and toolholders used on the mill.	Locate the various controls of the manual mill and move the table and mill head along each axis using those controls; demonstrate feed and speed controls.
2.	Basics of the Engine Lathe 115 This class describes the basic parts of the engine lathe as well as the cutting tools and workholding devices used on a typical lathe.	Locate the various controls of the manual lathe and move the turret along each axis using those controls; demonstrate feed and speed controls.
3.	Overview of Manual Mill Setup 200 This class describes the proper setup for a typical mill operation and explains how to determine mill settings, align mill components, and select proper tooling.	Align the mill head, the vise, and workpiece, and establish part zero for a sample part.
4.	Benchwork and Layout Operations 210 This class describes common benchwork operations performed on the mill before and after machining a part and describes common layout tools and procedures.	On a sample part, successfully hand tap a hole; hand ream a different hole within acceptable tolerances. Properly remove a broken tap, if required.
5.	Manual Mill Operation 220 This class guides you through the machining of a common part on the mill as well as explains common milling operations performed on the mill.	Demonstrate how to properly square each relevant surface on a rectangular part within acceptable tolerances.
6.	Engine Lathe Operation 225 This class guides you through the machining of a cylindrical part using inner- and outer-diameter cutting operations as well as explains general principles surrounding each operation.	Demonstrate how to properly turn a cylindrical part to a specified diameter within acceptable tolerances.
7.	Holemaking on the Mill 230 This class describes how to perform common holemaking operations on the manual mill and explains common principles about each holemaking process.	Demonstrate how to properly drill, bore, ream, and counterbore various holes on a mill to specifications.
8.	Threading on the Engine Lathe 235 This class describes the manual lathe components used for threading and explains how to cut and inspect an external and internal thread.	Demonstrate how to properly cut a single-point OD thread on the lathe; properly cut a single-point ID thread on a different sample part.

Mechanical Systems

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	Class	Offline Task
1.	Safety for Mechanical Work 105 This class describes safety precautions for performing maintenance on mechanical systems.	Identify the people in the work area most likely with the authority to lockout and tagout equipment; demonstrate all safety precautions when activating a conveyor system.
2.	Forces of Machines 110 This class identifies the various types of mechanical forces and describes how these forces act on objects. Includes an Interactive Lab.	For equipment used in the work space, find the force, torque, linear speed, and/or rotary speed of its mechanical components.
3.	Power Transmission Components 120 This class discusses the process of mechanical power transmission and describes the components used to transmit mechanical energy.	For three common types of equipment in the workplace, walk around each machine and identify the various mechanical power transmission systems.
4.	Lubricant Fundamentals 130 This class describes different types of industrial lubricants and explains the importance of proper lubrication procedure. Includes an Interactive Lab.	Identify the different types of lubricants used in the facility by smell and by touch; Use a grease gun to properly lubricate a machine.
5.	Mechanical Power Variables 200 This class discusses the variables involved in mechanical power transmission and how they affect industrial processes. *Includes an Interactive Lab.*	Run a motor; estimate the point at which the motor reaches optimal torque and speed.

Metal Cutting

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	Class	Offline Task
1.	Machines for Metal Cutting 130 This class identifies and describes the common machines used in metal cutting.	Demonstrate proper care of the ways and other key machine components for each machine used on the job.
2.	Cutting Processes 140 This class provides a comprehensive overview of the most common metal cutting operations performed in the shop. Includes an Interactive Lab.	Follow a job sheet for a particular part and gather all relevant tooling.

Quality

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	Class	Offline Task
1.	Troubleshooting: Identifying Problems 180 This class provides an introduction to the troubleshooting process and describes basic steps for identifying problems.	Name key members of a root cause analysis team; state the problem being addressed by the team's efforts.
2.	Troubleshooting: Understanding Causes and Effects 182 This class provides an introduction to the process of determining problem causes and effects.	Read a Pareto chart or other graphic tool produced by a troubleshooting team and explain the information communicated by the chart.
3.	Troubleshooting: Taking Corrective Actions 184 This class discusses ways to identify, implement, and document effective solutions in the troubleshooting process.	Show documentation that resulted from the work of a recent troubleshooting team.

Rigging

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	Class	Offline Task
1.	Rigging Mechanics 220 This class covers the mechanical laws involved in rigging, as well as essential practices for calculating the weight of a load and determining its center of gravity.	For a complex-shaped load of unknown weight, calculate the approximate weight and center of gravity; recommend a safe and effective rigging approach for the load.

Safety

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	Class	Offline Task
1.	Metalworking Fluid Safety 165 This class explains the health and safety risks inherent to working with metalworking fluids and also describes safe practices that help to reduce metalworking fluid exposure.	Check the concentration of coolant in a machine reservior; demonstrate how to prevent bacterial growth in the coolant.

Shop Essentials

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	Class	Offline Task
1.	Shop Algebra Overview 200 This class explains basic principles of algebra and demonstrates how to solve equations containing multiple operations.	For a series of equations used in a program, solve the equation for a variable by following the correct order of operations.
2.	Trig: Pythagorean Theorem 205 This class introduces the Pythagorean theorem and explains how to apply this rule to find unknown information in sample part drawings.	Use trig ratios to calculate the length of an unknown leg or hypotenuse for a series of right triangles in a sample print.
3.	Shop Trig Overview 210 This class presents a general overview and refresher for the rules of trigonometry.	For a series of sample right triangles, use trig ratios to find the missing side and/or angle.
4.	Trig: Sine, Cosine, and Tangent 215 This class explains how to use sine, cosine, and tangent to find information about the sides and angles of right triangles in sample shop prints.	Use trig ratios to calculate the amount of taper in a feature in a sample print.