Key Responsibilities and Required Skills for Die Maintenance Technician

🎯 Role Definition

The Die Maintenance Technician is a hands-on tooling and maintenance professional responsible for diagnosing, repairing, maintaining and optimizing dies, molds and stamping tooling to ensure high-volume production continuity, part quality, and press uptime. This role requires deep mechanical aptitude, experience with press die tryouts, tooling repair techniques (welding, brazing, EDM), precision measurement, blueprint/GD&T interpretation, and collaboration with production, tooling engineering and quality teams to reduce downtime and drive continuous improvement.

📈 Career Progression

Typical Career Path

Entry Point From:

Machine Operator / Press Operator with tooling exposure
Maintenance Technician (general mechanical)
Apprentice Tool & Die Maker

Advancement To:

Senior Die Maintenance Technician / Lead Tooling Technician
Tooling Engineer / Die Designer
Maintenance Supervisor / Plant Maintenance Manager

Lateral Moves:

CNC Machinist / EDM Operator
Production or Quality Engineer
Process Improvement Specialist

Core Responsibilities

Primary Functions

Diagnose and repair stamping dies, progressive dies, transfer dies and forming dies by disassembling tooling, identifying worn or broken components, and performing hands-on repair using welding, brazing, grinding and fabrication to restore dies to specification.
Conduct die try-outs and press adjustments on mechanical and hydraulic presses, identify root causes of press-related issues, and make fine adjustments to punches, dies, pilots and guides to achieve part tolerance and repeatability.
Perform preventive and predictive maintenance on dies and press tooling, develop and execute maintenance schedules, perform inspections, and replace wear items (strippers, springs, bushings, bearings, return pins) to minimize unplanned downtime.
Read and interpret engineering drawings, blueprints, and GD&T callouts to make accurate repairs, verify critical dimensions, and ensure corrected tooling meets part print requirements.
Operate and program EDM/wire EDM and other specialty equipment to repair intricate die components, cut keyways or restore core geometry that cannot be fixed by conventional fabrication techniques.
Fabricate replacement die components using manual machining, surface grinders, drill presses, lathes, and bench tooling when OEM parts are unavailable, ensuring dimensional accuracy and material compatibility.
Perform welding and brazing repairs on hardened tool steels and die components (including TIG/MIG and specialized brazing), followed by post-weld heat treatment or hardening grind as required.
Use precision measurement tools (micrometers, calipers, height gauges, indicators) and support coordinate measuring machines (CMM) data to validate part dimensions and tooling geometry after maintenance.
Collaborate with tool design and process engineering to implement tooling modifications that improve die life, reduce scrap, and improve throughput, documenting changes and updating tooling drawings.
Maintain detailed maintenance logs, repair records, tooling change histories and die condition documentation in the maintenance management system to support traceability and continuous improvement.
Set up and perform die changeovers safely and efficiently, following lockout/tagout (LOTO) procedures, ensuring tooling is aligned, bolted, and lubricated, and verifying correct part envelopes before production restart.
Troubleshoot hydraulic, pneumatic and press control issues related to die performance, coordinate with electrical/controls technicians when PLC or sensor issues affect tooling operation.
Develop and perform root cause analysis for repeat tooling failures, lead corrective action implementation (material changes, surface treatments, design changes) to prevent recurrence.
Train and mentor press operators and junior maintenance staff on proper die handling, daily checks, preventive maintenance tasks and best practices to extend die life and reduce production stoppages.
Manage die storage, preservation and logistics including cleaning, light preservation coatings, tagging, and secure storage to prevent corrosion, damage or misplacement of critical dies.
Coordinate with spare parts inventory and purchasing to maintain adequate levels of consumables and critical die components, recommend stocking levels based on historical failure data.
Inspect and repair die cushions, lifters, springs and return mechanisms; ensure die clearances and stop adjustments are within specification for safe press operation.
Support shut-downs, die builds and installations for new tooling, including assembly, bench testing, alignment and initial run-off to qualify tooling for production.
Implement 5S and lean tooling practices at the die room and press lines to improve workflow, reduce search time for tools/spares, and maintain a safe, efficient work area.
Participate in cross-functional production meetings, quality reviews and continuous improvement initiatives to address tooling-caused defects, process capability issues, and downtime trends.
Ensure compliance with site safety programs: perform LOTO, maintain protective guards during setups, use proper PPE, and follow all plant and regulatory safety requirements while performing maintenance and setup tasks.
Evaluate die repair vs. replacement economics, prepare cost and time estimates for tooling work, and communicate recommendations to tooling engineering and operations leadership.
Support quality inspections during and after die repairs to verify defect resolution, perform first article inspections (FAI) when tooling returns to production, and maintain records of validations.

Secondary Functions

Assist in basic CNC programming or preparation of machine programs for machining replacement tooling components.
Provide input to tooling capital projects by estimating lead times, labor hours and material requirements for new die builds.
Perform periodic condition reporting for tooling portfolio and help prioritize repair queues based on production criticality.
Participate in supplier/vendor coordination for outsourced die repairs, heat-treatment, plating, or specialty machining, including acceptance inspection and return-to-service testing.
Help develop standard operating procedures (SOPs) and preventive maintenance checklists specific to dies and press equipment.
Support continuous improvement pilots testing alternative tooling materials, coatings or lubrication strategies to extend die life.
Assist quality team with non-conformance investigations that appear to be tooling-related and help implement corrective actions.
Maintain and update tooling reference libraries, drawings and 3D models to reflect as-repaired geometries and modifications.
Provide backup support for general plant mechanical maintenance during peak workload periods.
Participate in on-call rotation for urgent tooling repairs during off-shifts or critical production runs.

Required Skills & Competencies

Hard Skills (Technical)

Extensive experience in die repair and maintenance for stamping, progressive, transfer, or forming dies.
Proficient in die tryout, press setup and changeover procedures for mechanical and hydraulic presses.
Skilled in precision measurement and inspection: micrometers, calipers, dial indicators, height gauges, and working with CMM output.
Strong blueprint reading and GD&T interpretation to ensure die repairs meet print tolerances.
Hands-on welding and brazing expertise for tool steel repair (TIG/MIG, braze techniques) and knowledge of post-weld hardening processes.
Operation and programming familiarity with EDM and wire EDM for precision die work.
Competence with manual and CNC machine tools for light fabrication: surface grinders, lathes, mills and drill presses.
Mechanical troubleshooting of press components, hydraulic/pneumatic systems and die-related motion systems.
Experience with die refurbishment techniques: hardfacing, plating, polishing, and surface treatments.
Use of maintenance management systems (CMMS) for work orders, history logging and spare parts tracking.
Knowledge of die materials, heat treatment requirements, and wear mechanisms to recommend durable solutions.
Basic electrical and controls awareness sufficient to identify sensor/PLC related die issues and coordinate fixes.
Familiarity with lean manufacturing tools: 5S, TPM, root cause analysis and continuous improvement methodology.

Soft Skills

Strong problem-solving and analytical skills with a bias for root cause resolution.
Excellent communication skills to collaborate with engineers, operators, suppliers and management.
Attention to detail and quality mindset to ensure repaired dies meet part specifications.
Time management and prioritization under production-pressure to minimize downtime.
Team player who mentors junior technicians and shares best practices.
Safety-first attitude and consistent adherence to lockout/tagout and plant safety protocols.
Adaptability to changing production schedules and tooling priorities.
Customer-service oriented — focused on supporting production needs and schedules.
Documentation discipline for accurate repair histories, SOP updates and maintenance logs.
Initiative to identify process improvements and propose cost-effective tooling solutions.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with technical coursework or on-the-job apprenticeship experience.

Preferred Education:

Trade school certificate, associate degree or diploma in Tool & Die, Machining, Industrial Maintenance or Manufacturing Technology.

Relevant Fields of Study:

Tool & Die Making
Machining / CNC Technology
Industrial Maintenance / Mechanical Technology
Welding Technology / Metallurgy

Experience Requirements

Typical Experience Range: 3–10 years performing die maintenance, toolroom repair, or similar hands-on tooling roles in high-volume manufacturing (stamping, automotive, appliance, electronics).

Preferred:

5+ years of progressive experience in die maintenance for stamping or progressive tooling.
Demonstrated history of die tryouts, EDM use, welding/brazing repairs, and successful reduction of tooling-related downtime.
Certifications such as Welding (AWS), Journeyman Tool & Die, OSHA 10/30, or manufacturer-specific press safety training are a plus.