Senior Setter

Key Responsibilities Production Setup & Machine Operation

• Interpret production documentation, engineering drawings and component layouts prior to machine setup.
• Prepare and set specialised gear cutting machinery and second operations equipment for production.
• Perform machine changeovers, setups and first-off approvals in accordance with engineering specifications.
• Optimise machine parameters to achieve required cycle times, quality standards and production efficiencies.
• Troubleshoot setup and production issues to minimise downtime and maximise machine availability.
• Ensure first-off components are approved before production commences.
• Minimise setup scrap and ensure all non-conforming components are correctly identified and segregated.

• Manufacture, assemble and maintain specialised tooling including press tools, milling fixtures, pneumatic tooling and custom production equipment.
• Perform precision machine adjustments to optimise machine performance and process capability.
• Diagnose machine faults and implement corrective actions to ensure reliable production.
• Carry out routine preventative maintenance and basic machine repairs.
• Escalate complex maintenance issues to the relevant technical support teams.
• Ensure tooling, Gear Hob sets and equipment are correctly labelled, maintained and stored.
• Monitor tooling condition and proactively request replacement tooling or spare parts where required.

• Collect and verify all gauges and measuring equipment in accordance with IMDS and calibration requirements.
• Conduct first-off inspections and work closely with Quality to achieve first-time approval.
• Monitor product quality throughout production runs and make adjustments where required.
• Identify process deviations, quality trends and root causes before defects occur.
• Implement corrective actions to maintain process capability and product conformity.
• Read and interpret technical manuals, engineering documentation and machine specifications.
• Maintain accurate production and quality records in accordance with company procedures.

• Drive continuous improvement initiatives focused on reducing setup times, improving machine efficiency and minimising waste.
• Identify opportunities to improve tooling, machine settings, workflows and production methods.
• Participate in Lean Manufacturing and 5S initiatives.
• Standardise best practices across machine setups and operational procedures.
• Contribute to productivity improvement projects and operational excellence initiatives.

• Provide structured training, coaching and technical guidance to machine operators.
• Support operator competency development and adherence to standard operating procedures.
• Assist operators in understanding machine functionality, quality requirements and setup standards.
• Promote knowledge sharing and continuous skills development within the department.

• Ensure all work is carried out in accordance with company Health & Safety procedures.
• Promote safe operating practices at all times.
• Maintain excellent housekeeping standards through adherence to 5S principles.
• Participate in safety inspections, audits and continuous safety improvement initiatives.
• Ensure work areas remain organised, clean and free from hazards.

• Work closely with Production, Engineering, Maintenance and Quality departments to ensure smooth production flow.
• Provide regular feedback to the Team Leader regarding production status, machine performance and technical issues.
• Escalate equipment failures, quality concerns and operational risks promptly.
• Build positive working relationships across all production support functions.

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