Key Responsibilities and Required Skills for Aluminum Helper

🎯 Role Definition

The Aluminum Helper supports metal fabrication and production teams by preparing aluminum stock, operating basic power and hand tools, assisting welders and fabricators, performing quality checks, maintaining a safe and organized work area, and ensuring timely completion of production tasks. This role is hands-on and physically active, focused on accuracy, repeatability, and adherence to shop safety and quality standards. Common settings include aluminum extrusion shops, window and door manufacturing, marine and automotive component production, and general metal fabrication facilities.

📈 Career Progression

Typical Career Path

Entry Point From:

General Laborer or Production Associate
High School Graduate with shop experience or technical school certificate
Warehouse or Shipping Associate transitioning into manufacturing

Advancement To:

Aluminum Fabricator / Assembly Technician
Welder (MIG/TIG) or Fabrication Specialist
CNC Operator (saws, routers, punching machines)
Shift Lead or Production Supervisor

Lateral Moves:

Sheet Metal Worker
Quality Inspector / Metrology Technician
Maintenance Technician / Machine Setter

Core Responsibilities

Primary Functions

Receive, stage and prepare aluminum extrusions and sheet stock for production runs by measuring, cutting, and organizing materials according to job travelers, work orders and production schedules to ensure workflow continuity and minimize downtime.
Operate manual and powered saws, shear machines, and cutoff equipment to cut aluminum to specified lengths while maintaining accurate tolerances and following standard operating procedures for setup and blade selection.
Assist fabricators and welders by holding and clamping components, aligning assemblies, and applying tack welds or fixtures as directed; ensure support work minimizes rework and speeds up cycle times.
Deburr, grind, sand and polish cut edges, holes and welds on aluminum parts using hand files, rotary deburring tools, bench grinders, and flap discs to meet finish and safety specifications.
Prepare surfaces for finishing operations including anodizing, powder coating and painting by cleaning, masking, scuffing and applying chemical pretreatments according to process checklists and MSDS guidelines.
Load and unload parts from saws, presses and finishing lines using manual handling techniques, lifting aids, or forklifts (if certified) to protect product quality and prevent workplace injuries.
Read and interpret basic blueprints, cut lists and production drawings to identify part numbers, dimensions, hole patterns and finish requirements; flag discrepancies to leads or engineers.
Measure and verify critical dimensions using calipers, micrometers, tape measures and gauges, and record measurements on inspection checklists or electronic systems as required for traceability.
Install fasteners, rivets and hardware using pneumatic rivet guns, hand riveters and power drivers; torque and verify assemblies to engineering specifications.
Assist with CNC saw and router operations by loading/unloading fixtures, clearing chips, and verifying part orientation while following job setup instructions.
Perform quality checks at defined stages—first-piece inspections, in-process verifications and final inspections—documenting defects and supporting containment and corrective actions.
Stage, pack and label finished assemblies for shipment, including protective wrapping, crating and palletizing to prevent damage during transport and to meet customer packaging requirements.
Maintain and clean workstations, tooling, fixtures and equipment; perform basic preventive maintenance such as blade changes, lubrication and visual checks to extend tool life and ensure safe operation.
Sort and segregate scrap and rework material, document scrap quantities, and prepare material for recycling in compliance with company scrap handling procedures and environmental requirements.
Apply sealants, adhesives, gaskets and weatherstripping to frames and assemblies following manufacturer instructions and curing procedures to achieve watertight and airtight seals.
Assist in bending and forming operations by setting up simple jigs, supporting brake operators and checking formed parts for fit and squareness to print.
Operate hand and pneumatic power tools (drills, grinders, impact drivers, sanders) safely and accurately to perform assembly, fabrication and finishing tasks.
Follow all shop safety, lockout/tagout, PPE and hot-work procedures; report hazards and participate in toolbox talks and safety audits to maintain a compliant work environment.
Support production teams in meeting daily throughput and quality targets by collaborating with lead hands, communicating status, and suggesting small process improvements.
Track and document production metrics, material usage and job completion status in paper travelers or basic MES/ERP systems as required by the production process.
Assist with fixture changeovers and simple jigs setup between runs to help reduce machine downtime and improve line changeover efficiency.
Train and mentor junior helpers or temporary staff on basic shop processes, safe tool use and quality expectations under supervision of leads.

Secondary Functions

Support inventory control by receiving raw materials, scanning barcodes, labeling material, and stacking stock in designated areas to maintain accurate inventory levels.
Participate in continuous improvement initiatives by providing feedback on workflow bottlenecks, tool ergonomics, and material handling methods that impact throughput.
Help housekeeping and 5S efforts across the shop by organizing tools, marking shadow boards, and ensuring aisles and exits remain clear for safety and efficiency.
Assist maintenance staff during scheduled downtime by providing access, removing guards, and performing simple tasks under supervision to expedite repairs and changeovers.
Support ad-hoc packing and light assembly tasks for urgent customer orders or prototypes, demonstrating flexibility and cross-functional teamwork across the production floor.

Required Skills & Competencies

Hard Skills (Technical)

Proficient in measuring and layout using calipers, micrometers, combination squares and tape measures to verify aluminum part dimensions and tolerances.
Experience operating manual and semi-automatic cutoff saws, cold saws, circular saws and band saws used for cutting aluminum extrusions and plate.
Skilled in deburring, grinding and finishing using bench grinders, rotary deburring tools, Scotch-Brite wheels and sanding equipment to produce smooth, defect-free edges.
Familiarity with rivet installation, pneumatic rivet guns, blind rivets, and basic mechanical fastening techniques for aluminum assemblies.
Hands-on knowledge of surface preparation for anodizing, powder coating and painting including masking, chemical cleaning and etching processes.
Ability to read and interpret basic blueprints, shop drawings and cut lists to identify part geometry, hole patterns and finish requirements.
Competent using hand and power tools including drills, drivers, air hammers, impact wrenches and torque tools with consistent quality and safety.
Basic experience assisting welding operations (MIG/TIG) by handling fixtures and parts, understanding heat-affected zones and grinding welds to profile.
Familiarity with basic quality inspection processes and documentation: first article inspections, in-process checks and final acceptance criteria.
Experience with material handling equipment such as pallet jacks, cranes, hoists and forklifts (certification preferred) for safe movement of large extrusions and assemblies.
Basic computer literacy to enter data into MES/ERP systems, scan barcodes, and update job status in production tracking tools.
Understanding of shop safety standards (OSHA) including PPE, lockout/tagout, hazard communication and hot work safety procedures.

Soft Skills

Strong attention to detail with consistent focus on dimensional accuracy and finish quality to reduce rework and scrap.
Reliable and punctual with a strong work ethic; able to meet shift schedules and production commitments.
Good communication and teamwork skills to coordinate with fabricators, supervisors and quality personnel on daily priorities.
Physical stamina and dexterity to perform lifting, standing, bending and repetitive tasks in a production environment.
Problem-solving mindset to identify minor defects, propose containment, and escalate issues to leads quickly.
Time management and organization to juggle multiple tasks during changeovers and high-volume runs.
Adaptability to learn new equipment, processes and finishing techniques in a fast-paced shop setting.
Positive attitude and willingness to take direction while contributing ideas for process improvement.
Commitment to continuous learning and upskilling to progress toward welding, CNC or fabrication technician roles.
Strong safety mindset and accountability for following protocols and encouraging safe behavior among peers.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED; basic math and measurement competency required.

Preferred Education:

Certificate from a trade school, technical college or apprenticeship program in welding, metal fabrication, CNC operation or manufacturing technology.

Relevant Fields of Study:

Welding Technology or Fabrication
Industrial Technology / Manufacturing
Sheet Metal / Mechanical Trades
Vocational/Technical Education in Machining or Metalworking

Experience Requirements

Typical Experience Range: 0–3 years of hands-on experience in metal fabrication, production assembly or general manufacturing; entry-level candidates with demonstrable shop skills are considered.

Preferred: 1–2 years of direct experience working with aluminum extrusion, deburring, basic assembly, and finishing operations; forklift or material handling certification a plus.