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Key Responsibilities and Required Skills for Die Setter

💰 $ - $

ManufacturingTool & DiePress OperationStampingMaintenance

🎯 Role Definition

The Die Setter is responsible for the precise installation, alignment, adjustment and maintenance of stamping, progressive, transfer and forming dies on mechanical and hydraulic presses. This role ensures die performance, product quality, press safety and production efficiency through expert setup, tryout, troubleshooting and preventive maintenance while collaborating with engineering, quality and production teams.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Press Operator (Mechanical or Hydraulic)
  • Machine Operator / Production Technician
  • Tool & Die Apprentice or Machinist Apprentice

Advancement To:

  • Senior/Master Die Setter
  • Tool & Die Maker / Toolroom Technician
  • Maintenance Technician – Reliability
  • Production Supervisor / Manufacturing Lead

Lateral Moves:

  • CNC Machinist / Programmer
  • EDM / Grind Department Specialist
  • Process Improvement / Manufacturing Engineer

Core Responsibilities

Primary Functions

  • Perform complete die changeovers on mechanical, hydraulic and servo-driven presses, including removal, installation, alignment, shimming and securing of die assemblies to meet production schedules and minimize downtime.
  • Conduct detailed die tryouts and first-article runs, tune press parameters and tooling clearances, and achieve part specifications through iterative adjustments and collaboration with quality and engineering.
  • Read, interpret and apply engineering drawings, blueprints, GD&T callouts, tooling drawings and setup sheets to ensure dies produce parts within dimensional tolerances and surface finish requirements.
  • Use precision metrology instruments (calipers, micrometers, height gauges, dial indicators, bore gauges) to measure, inspect and verify die components and finished parts, documenting results and corrective actions.
  • Diagnose and troubleshoot die and press issues—such as misfeeds, burrs, flashing, misalignment, part deformation and tool breakage—using root-cause techniques and hands-on mechanical adjustments.
  • Perform routine and preventative die maintenance: clean, lubricate, replace wear components (pads, springs, punches, bushings), recondition tooling faces and maintain accurate die logs and maintenance records.
  • Set up and program presses for progressive, transfer and deep-draw operations, including stroke, slide, feed, pressure and cushion adjustments to maximize part quality and cycle times.
  • Coordinate and execute quick die change (QDC) procedures and continuous improvement initiatives to reduce setup time (SMED), increase run-time and improve overall equipment effectiveness (OEE).
  • Operate and assist in die repairs and rebuilds, including basic welding, brazing, shimming, bench grinding, bushing replacement and collaborating with the toolroom for complex rework.
  • Perform tryout documentation and produce detailed setup sheets and tooling changeover instructions to ensure repeatable setups and minimize future downtime.
  • Collaborate with manufacturing engineering and quality to implement corrective actions, print revisions and tooling improvements based on production feedback and non-conformance reports.
  • Lead die trials for new product launches, validate tooling performance at production speeds and sign off on first-article inspections (FAI) in coordination with quality assurance.
  • Monitor die and press conditions during production runs, log runtime conditions and temperature variances, and proactively make adjustments to prevent scrap, die damage and press jams.
  • Maintain accurate tooling and die inventory records, tag tooling components, and coordinate with toolroom and purchasing to order critical spare parts and consumables.
  • Train and mentor junior die setters, press operators and maintenance staff on correct setup practices, safe handling of dies, changeover techniques and inspection procedures to build cross-functional capability.
  • Enforce and follow all safety protocols, lockout/tagout (LOTO) procedures, press guarding requirements and personal protective equipment (PPE) standards to reduce risk and comply with OSHA or site safety guidelines.
  • Utilize CNC, EDM and surface grinder resources as needed to prepare die surfaces, repair tooling, and provide precise fits during die maintenance and modification.
  • Participate in root-cause analysis, 8D or CAPA processes for recurring tooling or press issues; drive corrective action plans with measurable outcomes and timelines.
  • Implement continuous improvement ideas on die design, die maintenance and press setups that reduce cycle time, tooling wear, scrap rates and operational costs.
  • Support production planning by estimating setup times, providing accurate run-rate expectations and communicating tooling readiness and spare parts needs to planners.
  • Maintain cleanliness and organization of die storage, press rooms and tool cribs, ensuring dies are stored safely, tagged correctly and easily retrievable for changeovers.
  • Maintain and update die setup standards, tooling drawings and maintenance logs using digital systems (ERP, CMMS, or shop floor data tools) to ensure traceability and knowledge sharing.
  • Coordinate with external vendors and toolmakers for specialized repairs, heat treating, plating or complex die rework while ensuring vendor work meets company specifications.
  • Inspect and test die springs, guides, cams, and ejector systems; replace or adjust components to prevent misfeeds and ensure consistent part ejection and material flow.
  • Verify and set press timing and clutch/brake adjustments on mechanical presses; adjust hydraulic press parameters such as pressure, speed and dwell for forming operations.
  • Monitor material issues related to die performance—such as coil feed alignment, material thickness variation and surface contaminants—and work with material handling to correct root causes.
  • Ensure documentation of all die modifications, engineering change requests (ECR) and tooling deviations are recorded and communicated to relevant stakeholders.

Secondary Functions

  • Support continuous improvement and lean manufacturing projects focused on reducing scrap, setup time and cost per part.
  • Maintain die maintenance schedules and collaborate with maintenance/planning to optimize planned downtime for repairs and preventive maintenance.
  • Contribute to training materials, standard operating procedures (SOPs) and visual work instructions to promote standardized, safe and efficient die setup processes.
  • Assist quality team with special inspections, audits and corrective action documentation when tooling-related nonconformances occur.
  • Participate in cross-functional problem-solving meetings (Kaizen events, root cause workshops) to identify systemic issues impacting part quality and production flow.
  • Keep digital records current in ERP or CMMS systems for die history, repair actions and tooling inventory to maintain traceability and support future troubleshooting.
  • Support tooling procurement by specifying replacement parts, recommending preventive upgrades and participating in supplier evaluations for tooling services.
  • Provide feedback to design and process engineering to improve toolability, manufacturability and long-term durability of new and revised dies.
  • Help implement and maintain TPM (Total Productive Maintenance) and 5S practices within the die shop and pressroom to improve safety and organization.
  • Participate in cross-training programs to ensure backup coverage for press setup, die maintenance and weekend or off-shift changeovers when needed.

Required Skills & Competencies

Hard Skills (Technical)

  • Blueprint and technical drawing interpretation, including GD&T application for stamping and formed parts.
  • Extensive experience with die setup, tryout, troubleshooting and preventive maintenance on progressive, transfer and deep-draw dies.
  • Proficient with precision measurement tools: micrometers, calipers, height gauges, bore gauges, dial indicators and gauge blocks.
  • Knowledge of press mechanics and controls: mechanical, hydraulic and servo presses including timing, clutch/brake and slide adjustments.
  • Hands-on skills in basic die repair: bench grinding, bushing replacement, brazing, welding, shimming and surface rework.
  • Experience with EDM, CNC machining, surface grinding and toolroom support for complex die modifications.
  • Competence using shop floor digital systems: CMMS, ERP, maintenance logs, and digital setup/inspection records.
  • Ability to conduct root-cause analysis, 8D problem solving and to write clear corrective action reports.
  • Familiarity with quick die change (QDC) systems, die carts, die lifters, crane operation and safe material handling.
  • Knowledge of metallurgical considerations for tooling life: wear patterns, heat treatment, plating and material selection impacts.
  • Understanding of quality tools: SPC, first-article inspection (FAI), CMM basics and use of gauging systems.
  • Experience with SMED, TPM and lean manufacturing principles to reduce downtime and improve OEE.

Soft Skills

  • Strong mechanical intuition and hands-on troubleshooting mindset with attention to detail and process consistency.
  • Clear verbal and written communication to document setups, convey changeover procedures and report tooling conditions.
  • Team-oriented with the ability to collaborate across production, quality, maintenance and engineering teams.
  • Time management and prioritization skills to balance changeovers, maintenance tasks and production demands.
  • Continuous improvement mindset with the ability to identify inefficiencies and propose practical solutions.
  • Teaching and mentoring skills to develop junior staff and ensure transfer of tribal knowledge in the die shop.
  • Adaptability to shift work, variable production schedules and periodic overtime required for urgent changeovers or repairs.
  • Safety-first attitude with commitment to follow and enforce lockout/tagout and press safety standards.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with vocational or on-the-job training in manufacturing.

Preferred Education:

  • Technical certificate or associate degree in Tool & Die, Machining, Manufacturing Technology, or Industrial Maintenance.

Relevant Fields of Study:

  • Tool & Die Technology
  • Machining / Precision Manufacturing
  • Industrial Maintenance / Mechanical Technology
  • Manufacturing Engineering Technology
  • Welding and Fabrication

Experience Requirements

Typical Experience Range: 2–5 years of hands-on die setting, press setup and tooling maintenance on production stamping or forming equipment.

Preferred: 5+ years of progressive experience as a Die Setter, Tool & Die Maker or Toolroom Technician with demonstrated successes in tryouts, die rebuilds, and cross-functional process improvements.

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