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Key Responsibilities and Required Skills for Form Setter

💰 $ - $

ManufacturingTool & DieProductionMetal Forming

🎯 Role Definition

A Form Setter (also known as a Die Setter or Press Setup Technician) is responsible for setting up, adjusting, and maintaining forming, stamping, and bending equipment to produce parts that meet engineering specifications and company quality standards. This role blends mechanical setup, precision measurement, troubleshooting, and continuous improvement to ensure safe, efficient, and repeatable production runs.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Machine Operator / Press Operator
  • Apprentice Tool & Die Maker
  • Maintenance Technician (entry-level)

Advancement To:

  • Lead Form Setter / Senior Die Setter
  • Tooling Supervisor / Toolroom Lead
  • Maintenance Supervisor or Manufacturing Engineer
  • Production Supervisor / Plant Manager

Lateral Moves:

  • Quality Inspector / Metrology Technician
  • CNC Setter / Programmer
  • Industrial Maintenance Technician

Core Responsibilities

Primary Functions

  • Read, interpret and set up work orders, engineering drawings, blueprints, and tolerance specifications (including GD&T) to prepare presses, dies, and form tooling for production runs, ensuring first-piece conformity to specifications.
  • Install, align, shim, and secure dies, molds, and tooling on stamping presses, brake presses, punch presses, or roll-forming machines, verifying correct orientation and clamping torques.
  • Calibrate and adjust press parameters (stroke, tonnage, speed, cushion, feed) and machine controls to achieve target part dimensions, minimize scrap, and maintain cycle times.
  • Perform first article inspections and in-process dimensional checks using precision instruments (calipers, micrometers, height gauges, CMM input) and document results per quality procedures.
  • Troubleshoot and diagnose mechanical, hydraulic, pneumatic, and minor electrical issues on forming equipment; perform on-the-spot adjustments to maintain continuous production and reduce downtime.
  • Program and set up CNC-controlled presses and automated feeders (where applicable), including loading tool offsets, part programs, and servo settings for automated forming lines.
  • Perform preventive maintenance and basic repairs on tooling and machines (replace bushings, bearings, springs, wear plates) and escalate complex maintenance to the maintenance department when required.
  • Balance and fine-tune progressive dies and multi-station tooling to prevent part distortion, reduce noise and vibration, and extend tool life.
  • Verify material handling and feed systems are set correctly for material thickness, hardness, and coil width; adjust guides, lead-ins, and feeders to prevent jams and misfeeds.
  • Maintain accurate setup sheets, tooling logs, and changeover documentation (setup time, tooling used, run parameters) to support continuous improvement and reduce future setup time.
  • Collaborate with Production Planning and Toolroom to ensure die availability, schedule changeovers, and optimize production flow for on-time delivery.
  • Build and modify simple fixtures, guides, and hand tools to support runability and part handling while following safety and quality standards.
  • Train and mentor press operators and junior setters on proper setup techniques, inspection points, safe lockout/tagout procedures, and problem resolution best practices.
  • Participate in root-cause analysis for tooling failures, part defects, or production stoppages; propose corrective actions and implement tooling or process improvements.
  • Conduct pre-shift and post-shift inspections of tooling, safety devices, guards, and press condition; report and document abnormalities immediately.
  • Ensure compliance with plant safety policies and lockout/tagout (LOTO) procedures during setup, maintenance, and die changes to protect personnel and equipment.
  • Monitor scrap rates, downtime, and first-pass yield; implement adjustments and work with engineering to refine die designs and process parameters for improved quality.
  • Support die changeover and quick-change initiatives by developing and updating standardized setup processes, SMED (Single-Minute Exchange of Die) tools and checklists.
  • Maintain an organized and safe toolroom/press floor, including tool storage, tagging, preventive maintenance schedules, and calibration records for precision instruments.
  • Coordinate with Quality Engineering to incorporate inspection criteria, control plans, and SPC points into production setup and reporting.
  • Assist in tooling teardown, repair estimation, and communication with external tool vendors for complex refurbishments or rework.
  • Apply continuous improvement principles (Kaizen, 5S, TPM) to reduce cycle time, improve setup repeatability, and eliminate non-value-added activities across the press shop.

Secondary Functions

  • Support production planning by estimating setup times and tooling priorities for daily production schedules.
  • Maintain tooling inventory records, requisition replacement parts, and track die life for budgeting and capital planning.
  • Participate in safety audits, machine validation, and corrective action initiatives across the manufacturing floor.
  • Prepare and file setup documentation, production reports, and first-piece sign-offs into the manufacturing execution system (MES) or ERP.
  • Provide hands-on assistance during process change trials and new tool trials to validate manufacturability and production readiness.
  • Collaborate with engineering to suggest design-for-manufacturability (DFM) improvements that simplify setups and reduce scrap.
  • Help implement automation upgrades (robot end-of-arm tooling, auto feeders) by providing practical input on tooling interfaces and changeover impacts.
  • Support cross-functional continuous improvement teams to analyze yield losses, implement countermeasures, and quantify improvements.
  • Assist with basic programming tasks or parameter changes on PLCs and HMI panels under supervision, ensuring production safety.
  • Train on and enforce environmental, health, and safety (EHS) procedures related to material handling, lubricants, and metalworking fluids.

Required Skills & Competencies

Hard Skills (Technical)

  • Advanced die and tooling setup: installing, aligning, shimming, and securing dies and fixtures for stamping, forming, and bending operations.
  • Blueprint reading and engineering drawing interpretation, including Geometric Dimensioning & Tolerancing (GD&T) fundamentals.
  • Precision measurement and inspection using calipers, micrometers, height gauges, bore gauges, and CMM data interpretation.
  • Press machine operation and adjustment: mechanical, hydraulic, and servo press controls, including tonnage and stroke optimization.
  • Basic CNC setup and parameter adjustment for press brakes, turret punches, and automated forming lines.
  • Troubleshooting mechanical, hydraulic, and pneumatic systems; understanding of basic electrical and PLC interfaces.
  • Preventive maintenance and minor mechanical repair: bearings, bushings, aligning shafts, and replacing wear components.
  • Use of hand and power tools safely and effectively: torque wrenches, dial indicators, pullers, and precision alignment tools.
  • Familiarity with tooling maintenance best practices, die teardown, rework estimation, and vendor coordination.
  • Knowledge of SMED, TPM, Kaizen, and 5S methodologies to reduce changeover time and improve uptime.
  • Experience with MES/ERP systems, work order documentation, and basic data entry for production records.
  • Safety and compliance: lockout/tagout (LOTO), machine guarding, PPE, and hazard communication for press operations.

Soft Skills

  • Strong mechanical aptitude and attention to detail; thoroughness in first-piece inspection and setup documentation.
  • Problem-solving mindset with the ability to perform root-cause analysis and implement corrective actions.
  • Clear communication skills for cross-functional collaboration with production, quality, engineering, and toolroom teams.
  • Time management and prioritization to manage multiple setups, urgent changeovers, and competing production demands.
  • Team leadership and mentoring capability to train press operators and junior setters on safe, repeatable setups.
  • Adaptability to changing production schedules, tooling changes, and continuous improvement initiatives.
  • Customer-service orientation within internal customer contexts—responsive to production urgency and quality requirements.
  • Dependability and accountability for shift responsibilities, machine readiness, and adherence to safety rules.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED; vocational training or trade school certificate preferred.

Preferred Education:

  • Associate degree or certificate in Manufacturing Technology, Tool & Die, Industrial Maintenance, or Mechanical Technology.
  • Completion of a Tool & Die apprenticeship or equivalent manufacturer-specific training.

Relevant Fields of Study:

  • Manufacturing Technology
  • Tool & Die Making
  • Industrial Maintenance / Mechatronics
  • Mechanical Engineering Technology
  • Welding and Fabrication (supporting fixture fabrication)

Experience Requirements

Typical Experience Range:

  • 2–7 years of hands-on experience in press setup, die setting, or tooling within a metal stamping, forming, or manufacturing environment.

Preferred:

  • 5+ years as a Form Setter, Die Setter, or Toolroom technician with demonstrable experience in progressive die setup, CNC press brakes, GD&T application, and preventive maintenance programs. Experience with MES/ERP (e.g., SAP), TPM/SMED projects, and working in safety-conscious, high-volume production environments is highly desirable.
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