Earnings for machine operators can vary by size of the company, union or nonunion status, industry, and skill level and experience of the operator. Also, temporary employees, who are being hired in greater numbers, usually get paid less than company-employed workers. The median hourly earnings in 2002 for a variety of machine setters, operators, and tenders—metal and plastic were as follows:
| Model makers, metal and plastic | $18.27 |
| Patternmakers, metal and plastic | 16.09 |
| Metal-refining furnace operators and tenders | 14.79 |
| Lay-out workers, metal and plastic | 14.79 |
| Lathe and turning machine tool setters, operators, and tenders, metal and plastic | 14.55 |
| Tool grinders, filers, and sharpeners | 14.14 |
| Milling and planing machine setters, operators, and tenders, metal and plastic | 14.04 |
| Multiple machine tool setters, operators, and tenders, metal and plastic | 13.79 |
| Rolling machine setters, operators, and tenders, metal and plastic | 13.62 |
| Heat treating equipment setters, operators, and tenders, metal and plastic | 13.56 |
| Pourers and casters, metal | 13.40 |
| Drilling and boring machine tool setters, operators, and tenders, metal and plastic | 13.23 |
| Forging machine setters, operators, and tenders, metal and plastic | 12.64 |
| Grinding, lapping, polishing, and buffing machine tool setters, operators, and tenders, metal and plastic | 12.56 |
| Foundry mold and coremakers | 12.55 |
| Extruding and drawing machine setters, operators, and tenders, metal and plastic | 12.44 |
| Plating and coating machine setters, operators, and tenders, metal and plastic | 12.22 |
| Cutting, punching, and press machine setters, operators, and tenders, metal and plastic | 11.81 |
| Molding, coremaking, and casting machine setters, operators, and tenders, metal and plastic | 11.17 |
| All other metal workers and plastic workers | 13.65 |
Consider the parts of a toaster, such as the metal or plastic housing or the lever that lowers the toast. These parts, and many other metal and plastic products, are produced by machine setters, operators, and tenders—metal and plastic. In fact, machine tool operators in the metalworking and plastics industries play a major role in producing most of the consumer products on which we rely daily.
In general, these workers can be separated into two groups—those who set up machines for operation and those who tend the machines during production. Setup workers prepare the machines prior to production and may adjust the machinery during its operation. Operators and tenders primarily monitor the machinery during its operation, sometimes loading or unloading the machine or making minor adjustments to the controls. Many workers both set up and operate equipment. Because the setup process requires an understanding of the entire production process, setters usually have more training and are more highly skilled than those who simply operate or tend machinery. As new automation simplifies the setup process, however, less skilled workers also are increasingly able to set up machines for operation.
Setters, operators, and tenders usually are identified by the type of machine with which they work. Some examples of specific titles are drilling- and boring-machine toolsetters, milling- and planing-machine tenders, and lathe- and turning-machine tool operators. Job duties usually vary with the size of the firm and the type of machine being operated. Although some workers specialize in one or two types of machinery, many are trained to set up or operate a variety of machines. Newer production techniques, such as team-oriented “lean” manufacturing, require machine operators to rotate between different machines. Rotating assignments result in more varied work, but also require workers to have a wider range of skills.
Machine setters, operators, and tenders—metal set up and tend machines that cut and form all types of metal parts. Setup workers plan and set up the sequence of operations according to blueprints, layouts, or other instructions. They adjust the speed, feed, and other controls, choose the proper coolants and lubricants, and select the instruments or tools for each operation. Using micrometers, gauges, and other precision measuring instruments, they also may compare the completed work with the tolerance limits stated in the specifications.
Although there are many different types of metalworking machine tools that require specific knowledge and skills, most operators perform similar tasks. Whether tending grinding machines that remove excess material from the surface of machined products or presses that extrude metal through a die to form wire, operators usually perform simple, repetitive operations that can be learned quickly. Typically, these workers place metal stock in a machine on which the operating specifications have already been set. They may watch one or more machines and make minor adjustments according to their instructions. Regardless of the type of machine they operate, machine tenders usually depend on skilled setup workers for major adjustments when the machines are not functioning properly.
Machine setters, operators, and tenders—plastic set up and tend machines that transform plastic compounds—chemical-based products that can be produced in powder, pellet, or syrup form—into a wide variety of consumer goods such as toys, tubing, and auto parts. These products are manufactured by various methods, of which injection molding is the most common. The injection-molding machine heats and liquefies a plastic compound and forces it into a mold. After the part has cooled and hardened, the mold opens and the part is released. Many common kitchen products are produced with this method. To produce long parts such as pipes or window frames, an extruding machine usually is employed. These machines force a plastic compound through a die that contains an opening with the desired shape of the final product. Blow molding is another common plasticsworking technique. Blow-molding machines force hot air into a mold that contains a plastic tube. As the air moves into the mold, the tube is inflated to the shape of the mold, and a plastic container is formed. The familiar 2-liter soft-drink bottles are produced by this method.
Workers in three distinct specialties–setters, operators, and tenders—operate injection-molding machines. Most other types of plastic machines function in a similar manner. A typical injection-molding machine may have 25 different controls that can be adjusted. These workers are responsible for repairing any major problem. Operators monitor the many gauges on injection-molding machines, adjusting different inputs, pressures, and speeds to maintain quality.
Overall employment growth in the various machine setter, operator, and tender occupations will be slower than average, although employment trends among these occupations will diverge over the 2002–12 period. In general, employment of workers in the occupation will be affected by the rate of technological implementation, the demand for the goods they produce, the effects of trade, and the reorganization of production processes. Employment of multiple-machine-tool operators; molding, coremaking, and casting-machine operators, metal and plastic; and a number of miscellaneous operating occupations is expected to grow. A decline in employment, however, is projected for some machine tool operators, including metal-refining furnace operators and tenders and pourers and casters, metal. Despite differing rates of employment change, a large number of machine setter, operator, and tender jobs will become available due to an expected surge in retirements as some baby boomers become eligible for retirement by the end of the decade.
One of the most important factors influencing employment change in this occupation is the implementation of labor-saving machinery. In order to remain competitive by improving quality and lowering production costs, many firms are adopting new technologies, such as computer-controlled machine tools and robots. Computer-controlled equipment allows operators to tend a greater number of machines simultaneously and often makes setup easier, thereby reducing the amount of time setup workers spend on each machine. Robots are being used to load and unload parts from machines. The lower skilled manual machine tool operators and tenders are more likely to be eliminated by these new technologies, because the functions they perform are more easily automated.
The demand for machine setters, operators, and tenders—metal and plastic largely mirrors the demand for the parts they produce. The consumption of plastic products has grown as they have been substituted for metal goods in many consumer and manufactured products in recent years. The process is likely to continue and should result in stronger demand for machine operators in plastics than in metal.
Both the plastics and metal industries, however, face stiff foreign competition that is limiting the demand for domestically produced parts. One way in which larger U.S. producers have responded to this competition is by moving production operations to other countries where labor costs are lower. These moves are likely to continue and will further reduce employment opportunities for many machine operators, setters, and tenders—metal and plastic in the United States. Another way domestic manufacturers compete with low-wage foreign competition is by increasing their use of automated systems, which can make manufacturing establishments more competitive by improving their productivity. However, increased automation also limits employment growth.
Workers with a thorough background in machine operations, exposure to a variety of machines, and a good working knowledge of the properties of metals and plastics will be best able to adjust to the changing environment. In addition, new shop-floor arrangements will reward workers with good basic mathematics and reading skills, good communication skills, and the ability and willingness to learn new tasks. As workers adapt to team-oriented production methods and operate more machines, the number of multiple-machine-tool operators, setters, and tenders—metal and plastic will continue to rise.
Machine setters, operators, and tenders—metal and plastic learn their skills on the job. Trainees begin by observing and assisting experienced workers, sometimes in formal training programs. Under supervision, they may start as tenders, supplying materials, starting and stopping the machine, or removing finished products from it. Then they advance to the more difficult tasks performed by operators, such as adjusting feed speeds, changing cutting tools, or inspecting a finished product for defects. Eventually, they become responsible for their own machines.
The complexity of the equipment largely determines the time required to become an operator. Most operators learn the basic machine operations and functions in a few weeks, but they may need a year to become skilled operators or to advance to the more highly skilled job of setter. Although many operators learn on the job, some community colleges and other educational institutions offer courses and certifications in operating metal and plastics machines. In addition to providing on-the-job training, some employers send promising machine tenders to operator classes. Other employers prefer to hire workers who have completed, or currently are enrolled in, a training program.
Setters or technicians normally need a thorough knowledge of the machinery and of the products being manufactured, because they often plan the sequence of work, make the first production run, and determine which adjustments need to be made. Strong analytical abilities are particularly important for this job. Some companies have formal training programs for operators and setters; often, the programs combine classroom instruction with on-the-job training.
Although no special education is required for many jobs in the occupation, employers prefer to hire applicants with good basic skills. Many require employees to have a high school education and to read, write, and speak English. Because machinery is becoming more complex and shop-floor organization is changing, employers increasingly look for persons with good communication and interpersonal skills. Mechanical aptitude, manual dexterity, and experience working with machinery also are helpful. Those interested in becoming machine setters, operators, and tenders can improve their employment opportunities by completing high school courses in shop and blueprint reading and by gaining a working knowledge of the properties of metals and plastics. A solid math background, including courses in algebra, geometry, trigonometry, and basic statistics, also is useful.
Job opportunities and advancement can be enhanced as well by becoming certified in a particular machining skill. The National Institute for Metalworking Skills has developed standards for machine setters, operators, and tenders—metal. After taking a course approved by the organization and passing a written exam and performance requirement, the worker is issued a credential that signifies competence in a specific machining operation. The Society of Plastics Industry, the national trade association representing plastics manufacturers, also certifies workers in that industry. To achieve machine-operator certification, 2 years of experience operating a plastics-processing machine is recommended, and one must pass a computer-based exam.
Advancement for operators usually takes the form of higher pay, although there are some limited opportunities for operators to advance to new positions as well. For example, they can become multiple-machine operators, setup operators, or trainees for the more highly skilled position of machinist, tool and die maker, or computer-control programmer or operator. Some setup workers may advance to supervisory positions. (See the statements on machinists, computer-control programmers and operators, and tool and die makers elsewhere in the Handbook.) .
Workers in occupations closely related to machine setters, operators, and tenders—metal and plastic include machinists; tool and die makers; assemblers and fabricators; computer-control programmers and operators; and welding, soldering, and brazing workers. Often, machine operators are responsible for checking the quality of parts being produced, work similar to that of inspectors, testers, sorters, samplers, and weighers.
For general information about metal machine setters, operators, and tenders, contact any of the following organizations:
For information on schools and employers with training programs in plastics, contact:
In this process, heat is applied to metal pieces, melting and fusing them to form a permanent bond. Because of its strength, welding is used in shipbuilding, automobile manufacturing and repair, aerospace applications, and thousands of other manufacturing activities. Welders use many types of welding equipment set up in a variety of positions, such as flat, vertical, horizontal, and overhead. They may perform manual welding, in which the work is entirely controlled by the welder, or semiautomatic welding, in which the welder uses machinery, such as a wire feeder, to perform welding tasks. Like arc welding, soldering and brazing use molten metal to join two pieces of metal.
Summary of: http://www.bls.gov/oco/ocos226.htm
Employment of most manual machine tool operators is expected to decline, while that of multiple and computer-controlled machine tool operators will grow. These parts, and many other metal and plastic products, are produced by metalworking and plastics-working machine operators. Set-up workers prepare the machines prior to production and may adjust the machinery during operation. As new automation simplifies the setup process, however, less skilled workers are also increasingly able to set up machines for operation. They adjust speed, feed, and other controls, choose the proper coolants and lubricants, and select the instruments or tools for each operation.
Summary of: http://www.umsl.edu/services/govdocs/ooh20002001/357.htm
Next, operators thread the needle and mount attachments. If the machine operates automatically, they position the item under clamps. Sometimes they fold or stretch the material in a certain way to make the sewing easier. Work ActivitiesThe following list of occupational tasks is specific to this career. They like to be treated fairly and have supervisors who will back them up.
Summary of: http://www.iseek.org/sv/13000.jsp?id=100447
These machines cut, shape, drill, or otherwise modify metal or plastic parts. The computer program tells the machine which tools to use and how to use them. Operators mainly set up, tend, and maintain the machines. They load the machine controller (computer) with instructions or programs. Work ActivitiesThe following list of occupational tasks is specific to this career.
Summary of: http://www.iseek.org/sv/13000.jsp?id=100048
A few weeks of on-the-job training is sufficient for most workers to learn basic machine operations, but several years are required to become a highly skilled operator or setter. In fact, machine tool operators in the metalworking and plastics industries play a major role in producing most of the consumer products on which we rely daily. Setup workers prepare the machines prior to production and may adjust the machinery during its operation. Many workers both set up and operate equipment. Because the setup process requires an understanding of the entire production process, setters usually have more training and are more highly skilled than those who simply operate or tend machinery.
Summary of: http://www.bls.gov/oco/ocos224.htm
Growth in employment will be limited as more and more new, more productive computerized printing presses are used facilitating a shift to printing-on-demand. Printing Machine Operator Career and Job Description Printing machine operators are in charge of preparing, operating, and maintaining the printing presses found in a pressroom. Offset lithography, which transfers an inked impression from a rubber-covered cylinder to paper, is the most common form of printing process. They also send the material through the press cylinders adjusting the feed and tension settings as necessary. If a press stops due to paper jams or tears, workers must fix the problem as fast as possible to avoid excessive downtime.
Summary of: http://www.careeroverview.com/printing-machine-operator-careers.html
Because the textile industry is highly automated, persons with technical skills and some computer training will have the best opportunities. Night and weekend shifts are common, because many textile and fiber mills operate 24 hours a day. These workers are responsible for numerous machines that they start, stop, clean, and monitor for proper functioning. Workers adjust the flow of fiber base through the spinneret, repair breaks in the fiber, and make minor adjustments to the machinery. Textile machinery operators play a vital role in all of the various processes described above.
Summary of: http://www.umsl.edu/services/govdocs/ooh20002001/128.htm
Some factories pride themselves on hand-crafted solid-wood furniture, while others have highly automated assembly lines that mass-produce inexpensive pieces. Machine operators run the machines that turn raw materials into the pieces that assemblers put together to make the finished product. The exact skills and duties of furniture workers vary greatly. Operating some of these machines and tools requires training and skill. For information on apprenticeships, see Virginia's Career Connect.
Summary of: http://www3.ccps.virginia.edu/career_prospects/briefs/E-J/Furniture.shtml
Most receive on-the-job training from their companies, manufacturers’ representatives, and experienced workers. Job opportunities will be best for individuals with experience using computers and digital technology. Photographic processing machine operators operate various machines, such as mounting presses and motion picture film printing, photographic printing, and film developing machines. Film process technicians operate machines that develop exposed photographic film or sensitized paper in a series of chemical and water baths to produce negative or positive images. They then load the film in the machine, which immerses the exposed film in a developer solution.
Summary of: http://www.collegegrad.com/careers/produ21.shtml