CMM Programmer

The CMM / 3D Scan Programmer creates, validates, and maintains dimensional inspection programs for tactile CMMs and non-contact 3D scanning systems. This role is the plant's technical owner of inspection programs and equipment health: interpreting GD&T on customer drawings, building robust Polyworks, PC-DMIS and/or ZEISS Calypso programs, recovering equipment quickly when faults occur, and diagnosing whether a problem lies in the part, the fixture, the program, or the machine.

The programmer works closely with Engineering, Production, and the Quality team to deliver accurate, timely dimensional data for production, launches, PPAP, and problem solving.

• Develop, debug, and optimize CMM programs in PC-DMIS and/or ZEISS Calypso from 2D drawings and 3D CAD models for as-cast and machined aluminum components.
• Build alignments that correctly reflect the drawing's datum reference frame, including datum targets and datum schemes typical of castings.
• Develop and maintain 3D scan inspection routines (surface comparison, sections, feature extraction) using structured-light scanning software such as ZEISS INSPECT / GOM, Poly Works, or equivalent.
• Select appropriate probe and stylus configurations, sampling strategies, filtering, and scan settings to balance measurement accuracy against cycle time.
• Manage program revisions under document control and update programs promptly when drawings, CAD models, or customer requirements change.
• Design or specify inspection fixtures and holding methods in collaboration with Engineering and validate fixtures before release.

• Interpret engineering drawings and GD&T per ASME Y14.5 and ISO GPS (ISO 1101 and related standards) as required by each customer.
• Translate feature control frames, material condition modifiers, and datum precedence into correct measurement and evaluation methods.
• Support drawing reviews and PPAP feasibility by identifying characteristics that are ambiguous, unmeasurable, or at risk with the planned inspection method.
• Explain GD&T results clearly to engineers, operators, and customer representatives.

• Recover CMMs and scanning systems after crashes, collisions, E-stops, controller faults, communication losses, and software errors, restoring equipment to validated operating condition.
• Perform probe and stylus qualification, reference sphere calibration, probe changer and rotary table checks, and scanner calibration and verification.
• Diagnose the root cause of abnormal results, distinguishing among part condition, fixture and clamping, program logic, alignment, environmental (temperature, vibration, air supply), and machine issues.
• Coordinate with OEM service providers (e.g., Hexagon, ZEISS) for repairs, annual calibration, and software support; provide clear fault descriptions and supporting evidence.
• Maintain preventive maintenance schedules, critical spare parts (styli, probe modules, filters), and equipment downtime logs.
• Develop recovery guides and quick-reference instructions so operators can safely handle common faults.

• Plan and conduct measurement system analysis (Gage R&R, bias, linearity, stability) per the AIAG MSA manual and customer-specific requirements.
• Perform correlation studies between CMM, 3D scan, CT, and customer measurement results, and resolve discrepancies.
• Monitor the metrology lab environment and apply temperature compensation practices appropriate for aluminum parts.
• Support calibration records and measurement uncertainty considerations for audits.

• Generate full dimensional layouts, ballooned-drawing results, and capability data for PPAP submissions and new program launches.
• Support tool and die trials with fast-turnaround dimensional data and clear deviation reporting.
• Provide dimensional analysis for customer concerns, containment, and root cause investigations (8D, 5-Why, Ishikawa).
• Present color maps, trend data, and dimensional findings to internal teams and customers.

• Create clear, standardized inspection reports and maintain organized, traceable measurement data.
• Feed dimensional data into SPC and statistical tools to support process control and trending.
• Train and mentor Manager and supervisors to meet production and launch demands.
• Follow all EHS requirements and maintain 5S standards in the metrology lab.
• CMM operators and quality…