Shaper Operator, Gears

Key Responsibilities

• The ability to read and understand engineering drawings / blueprints.  Study sample parts, blueprints, drawings, and engineering information to determine methods and sequences of operations needed to machine parts and determine product dimensions and tolerances.
• Select the proper tooling for the designated operation / part / machine.
• Shaper operators must be capable of handling large and heavy gear blanks to load onto machines and unload using overhead cranes. Gear blanks need to be guided for location on fixtures, aligned and properly clamped to fixtures so that the parts will not shift while hobbing. Some overhead and extended reach motion may be required to secure parts and cutting tools to machines and to machine tables.
• Line up production parts and tooling by calculating dimensions and tolerances using knowledge of mathematics and instruments such as micrometers, dial indicators, gage blocks and calipers.
• Maximize feeds and speeds to produce a quality product, as the specific operation requires, in the most cost-effective manner.
• Shaper Operator will be self-motivated to initiate continuous improvements, implementing cost saving methods for machine set-up and operation.
• Observe and listen to operating machines or equipment to diagnose machine malfunctions and to determine need for adjustments or repairs.
• Machine parts to specifications.
• Measure, examine, and test completed units to detect defects and ensure conformance to specifications, using precision instruments such as micrometers.
• The Shaper Operator will operate several vertical gear shaping machines.
• Set up gear cutting machines by selecting and installing appropriate tools and fixtures
• Operate machines to cut, shape, and finish gears using processes such as hobbing, gashing, or shaping
• Monitor machine operations to ensure accuracy and quality of gears produced
• Inspect finished gears using precision measuring tools like gear tooth calipers, micrometers, and gauges
• Perform in-process quality checks and verify critical dimensions to ensure compliance with engineering tolerances
• Maintain machine cleanliness and perform routine preventive maintenance and daily operator care and cleaning of gear cutting equipment
• Document production data, inspection results, and any nonconformances; promptly communicate machine or quality issues to supervision
• Collaborate with quality, engineering, and production teams to ensure proper interpretation of requirements and continuous process improvement
• Train and mentor junior operators as needed
• Adherent to all safety procedures, including proper rigging and handling of large and heavy components

• Education: High school diploma or equivalent 
• Experience:  2–5 years of experience shaping gears or related machine shop equipment 
• Ability to read and interpret engineering blueprints
• Must be physically capable of performing duties throughout shift.
• Must be a team player and should possess good communication skills.

• This position requires strong mechanical aptitude, attention to detail, and the ability to work independently on large-scale, high-value components in a heavy industrial manufacturing environment.