Gear Grinder A

Flender•Elgin, IL

17d•$35 - $40•Onsite

About The Position

This position typically requires 8+ years of experience in precision grinding or a similar field and 3+ years specifically in profile grinding of gears or gear-related components. Working with minimal technical supervision, the Skilled Gear Grinder performs complex set‑ups and grinding operations on profile gear grinding machines to produce and finish gears and gear components to very close tolerances and stringent quality requirements. The employee independently interprets blueprints, process sheets, and work instructions, selects and mounts workholding, grinding wheels, and dressing tools, programs/edits CNC profile grinding cycles as required, determines operation sequences and grinding strategies, and performs in‑process inspection and makes necessary corrections to maintain tolerances. The Skilled Gear Grinder uses all required precision measuring equipment, and understands gear geometry (e.g., involute profile, lead, pitch). At this level the employee acts as a technical resource for less experienced grinders and machinists, provides on‑the‑job training to new employees, actively participates in process improvements, and has a proven track record of improvement submissions. May perform other duties as assigned by supervisor. May be required to oversee quality, workmanship and training of fellow team members and, as assigned, perform the role of lead person.

Requirements

8+ years of experience in precision grinding or a similar field
3+ years specifically in profile grinding of gears or gear-related components
Ability to interpret blueprints, process sheets, and work instructions
Ability to select and mount workholding, grinding wheels, and dressing tools
Ability to program/edit CNC profile grinding cycles
Ability to determine operation sequences and grinding strategies
Ability to perform in-process inspection and make necessary corrections
Proficiency with precision measuring equipment
Understanding of gear geometry (e.g., involute profile, lead, pitch)
Experience working with alloy and case-hardened steels
Awareness of grinding burn and microstructural damage
High school diploma or equivalent required
Capability to meet productivity requirements as listed on route sheets
Minimum of 40 hours per week and adherence to the company’s written attendance policy
EH&S safety training according to the EH&S training matrix for this job
Crane operation and safety
Fork truck safety and operation
Proper use of chains, shackles, straps, and compliance with the rigging inspection/tagging SOP
Wood and recyclable material disposal per plant standards
ISO basics and applicable quality management (QM) documentation
Internal and advanced work standards relevant to gear grinding
Blueprint and gear drawing reading (gear data, tolerances, GD&T)
Parts identification and use of part lists and SAP (or other ERP) transactions
Measuring equipment use, including gear measuring equipment, micrometers, vernier calipers, bore gages, and form/lead testers

Nice To Haves

Completion of an apprenticeship, vocational training, or technical degree in machining, toolmaking, or related field preferred
Training on the Barkhausen device and evaluation criteria will be provided
Operate a secondary machine (e.g., gear inspection equipment, hard turning, or other grinding operations) within training and capability
Voluntary overtime may be required when production schedules demand it

Responsibilities

Set‑Up & Operation – Profile Gear Grinding Machines: Load, clamp, align, and center gear workpieces and mandrels. Set up and operate assigned profile gear grinding machines (e.g., Niles, Pfauter, Liebherr, Höfler, or equivalent). Adjust fixturing, machine offsets, and process parameters to achieve required tolerances and surface finish.
Programming and Process Definition: Program or modify CNC profile grinding programs as needed to meet drawing and process requirements. Determine and optimize operation sequences for profile, lead, and root grinding. Select and set dressing parameters for grinding wheels and form rolls.
Inspection, Measurement & Documentation: Perform in‑process and final inspections using appropriate measuring equipment (e.g., gear measuring centers, lead/profile testers, micrometers, calipers, indicators, surface roughness gauges). Read and interpret gear inspection charts and make corrections to maintain tolerances. Prepare and maintain productivity, capacity, and quality figures according to given schemes and work standards.
Troubleshooting & Problem Solving: Independently analyze grinding problems (burn, chatter, profile/lead deviations, taper, runout, size variation). Implement corrective actions related to wheel selection, dressing, coolant, feeds/speeds, and clamping methods. Analyze error incidence and support root‑cause analysis and corrective actions.
Machine Care, Maintenance & Housekeeping: Monitor service intervals, perform assigned preventive maintenance, and carry out cleaning tasks to keep machines in good working order. Respond promptly to machine alarms and minor mechanical issues and coordinate with maintenance as required. Maintain a clean and orderly work area in compliance with 5S standards.
Barkhausen noise: Operate Barkhausen noise measurement equipment to detect grinding burn and surface damage on ground parts as required by the control plan. Training on the Barkhausen device and evaluation criteria will be provided.
Training & Support of Others: Provide structured training and guidance for new grinders and machinists on profile grinding processes, safety, and quality requirements. Share best practices and act as a subject matter expert for gear grinding operations.
Cross‑Training and Flexibility: As required, operate a secondary machine (e.g., gear inspection equipment, hard turning, or other grinding operations) within training and capability. Machine training assignments are determined by the supervisor based on the cross‑training matrix and business needs.
Communication & Teamwork: Maintain good communication and professional behavior with supervisors, quality personnel, maintenance, and fellow team members. Report deviations, nonconformances, and safety concerns promptly and constructively.
Production Planning & Performance: Ensure targeted dates, capacities, and productivity requirements are met, according to route sheets and supervisor direction. Support continuous improvement in throughput, set‑up time, and first‑pass yield.
Safety & Compliance: Operate cranes, fork trucks, and rigging (chains, shackles, straps) only when trained and authorized, and in compliance with plant SOPs. Follow the SOP for Inspection of Lifting Slings, Chains, and Shackles when using rigging equipment. Adhere to all EH&S, ISO, and internal quality requirements and work standards.
Continuous Improvement participation: Maintain a proven record of improvement submissions or equivalent improvement activities, including cost‑saving and safety‑related ideas. Actively participate in problem‑solving teams and improvement workshops.
Initiates orders for tools, fixtures, grinding wheels, dressing tools, and supplies as needed.
Performs general cleaning and housekeeping to keep the department as clean and organized as possible.