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Key Responsibilities and Required Skills for Gear Cutter

💰 $40,000 - $70,000

ManufacturingMachiningProduction

🎯 Role Definition

A Gear Cutter (also known as a gear hobbing/shaping operator or gear machinist) is responsible for accurately machining gear teeth using hobbing, shaping, slotting, and CNC gear cutting equipment. The role includes interpreting blueprints and gear specifications (module/pitch/helix/backlash), setting up and optimizing machines, performing in-process and final inspection to AGMA/ISO quality standards, troubleshooting process issues, maintaining tooling and fixtures, and collaborating with engineering and quality teams to deliver high-quality gears on schedule. This role demands strong metrology skills, mechanical aptitude, adherence to safety protocols, and a continuous-improvement mindset.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Machine Operator / Production Machinist
  • Apprentice or Trade School Machining Graduate
  • CNC Lathe/Mill Operator

Advancement To:

  • Lead Gear Cutter / Setup Lead
  • Gear Shop Supervisor / Production Supervisor
  • Process Engineer / Manufacturing Engineer
  • CNC Programmer or Tooling Engineer

Lateral Moves:

  • Gear Grinder / Finishing Specialist
  • Quality Inspector / Metrology Technician

Core Responsibilities

Primary Functions

  • Set up, program (when applicable) and operate gear hobbing machines (manual and CNC), gear shapers, slotters and related gear cutting equipment to produce helical, spur and worm gears to print specifications, ensuring correct hob selection, speed/feed settings and coolant usage.
  • Read and interpret engineering drawings, gear specifications, GD&T callouts, module/pitch/diameter/helix angle and inspection reports to determine machining sequences, tooling requirements and critical tolerances for each gear.
  • Perform complete machine setups including fixture and workholding selection, hob or cutter mounting and alignment, centerline and pitch adjustments, and perform trial cuts to verify tooth profile and concentricity before production.
  • Measure gear features in-process and post-process using gear-specific metrology tools (gear tooth calipers, pitch micrometers, dial indicators, gear inspection fixtures) and log measurements against AGMA or customer quality criteria.
  • Operate coordinate measuring machines (CMM), roll testers, profile projectors and form testers to validate tooth profile, lead, runout and backlash, and generate inspection documentation and first article reports.
  • Adjust machine parameters and tooling offsets based on inspection feedback to optimize tooth form, minimize scrap, and maintain required surface finish and dimensional accuracy.
  • Program and edit CNC gear hobbing and milling offsets for Fanuc/Siemens/Heidenhain controls (or equivalent), including inputting tool geometry, spindle/axis speeds and interpolation settings when required.
  • Setup and run production batches to meet order schedules and takt times, monitor cycle times, change tooling and fixtures between part numbers, and ensure accurate part counts and traveler completion.
  • Perform preventative maintenance and basic repair on gear cutting machines and hubs (lubrication, hob dressing, cleaning, bearing checks), identify out-of-spec machine behaviors and escalate to maintenance when necessary.
  • Maintain and manage toolroom inventory: knives, hobs, cutters, collets, fixtures and spindle tooling; inspect incoming tooling and report wear or damage that could affect part quality.
  • Deburr, chamfer and perform light secondary finishing operations on gear components as required; coordinate with gear grinding and heat-treatment shops for subsequent processes.
  • Ensure full compliance with safety protocols, lockout/tagout procedures, proper use of PPE and safe handling of cutting fluids and lubricants to maintain a safe shop floor environment.
  • Create and maintain clear, accurate process documentation, setup sheets, production logs and inspection records for traceability and continuous improvement purposes.
  • Troubleshoot production issues such as chatter, tool vibration, inconsistent tooth form or surface finish, root cause analysis and implement corrective actions to reduce downtime and scrap.
  • Collaborate with design and process engineering to develop fixturing, select optimal tooling and recommend design-for-manufacture improvements to simplify setups and reduce cycle time.
  • Implement and support lean manufacturing and 5S initiatives in the gear production area, suggesting and piloting process improvements that result in time, cost or quality benefits.
  • Train, mentor and cross-train junior operators and apprentices on gear cutting theory, machine setup, metrology best practices and safety procedures to grow team capability.
  • Coordinate with heat-treat vendors and internal departments to ensure proper sequencing of operations (machining before/after heat treatment) and account for distortion or hardness changes in finish machining.
  • Monitor and apply Statistical Process Control (SPC) techniques, document process capability, and escalate nonconforming conditions to Quality while participating in corrective action plans and containment activities.
  • Communicate with production planning, quality and customers (when required) to resolve part deviations, delivery issues and to provide technical input for quotes, lead times and capacity planning.
  • Maintain awareness of new tooling materials, coating technologies, and gear-cutting machine capabilities; recommend investments or trials that could improve productivity, tool life or finish.
  • Ensure work complies with customer-specific requirements and industry standards including AGMA and ISO, and prepare parts and documentation for external audits and supplier assessments as needed.

Secondary Functions

  • Assist in layout and assembly of fixtures and nesting of parts for batch production to maximize material utilization and throughput.
  • Support tooling trials and prototype runs, providing feedback to R&D and engineering on manufacturability and quality of early-production gears.
  • Participate in cross-functional continuous improvement teams, Kaizen events and root cause investigations to drive waste out of the process.
  • Help maintain production KPIs and participate in daily standups or shift handovers to communicate status, quality alerts and maintenance needs.
  • Provide input to purchasing for replacement tooling, cutting fluids and consumables based on usage patterns and process demands.
  • Aid in documenting best practices and standard work instructions for new part introductions and recurring jobs.
  • Support ad-hoc troubleshooting for downstream processes (grinding, heat treat, assembly) when gear-related issues are suspected.

Required Skills & Competencies

Hard Skills (Technical)

  • Gate-to-gate experience with gear hobbing and shaping operations on machines such as Gleason, Liebherr, Wenzel, KAPP, or similar gear-specific equipment.
  • Proven capability to read and interpret engineering drawings, including GD&T, gear notation (module, diametral pitch, pressure angle, helix) and tolerance stacks.
  • Proficiency in gear inspection and metrology: use of CMM, gear roll testers, profile projectors, pitch micrometers, form gauges and tooth thickness gauges.
  • Hands-on experience with CNC controls (Fanuc, Siemens, Heidenhain) for gear hobbing/milling and ability to enter and edit offsets and parameters.
  • Knowledge of AGMA and ISO gear quality standards, and ability to apply those standards in inspection and acceptance criteria.
  • Familiarity with heat-treat effects on gears (distortion, hardness) and experience compensating for these in finish machining operations.
  • Strong mechanical troubleshooting: diagnosing chatter, runout, cutter wear, machine backlash and other causes of gear defects.
  • Working knowledge of tool selection and tool life management for hobs, cutters and indexable tooling, including coating and carbide grades.
  • Experience with SPC, process capability studies and ability to maintain process control charts and inspection records.
  • Basic preventative maintenance skills and the ability to perform machine alignments, spindle checks and hob dressing.
  • Competence with common shop software: CAM, ERP/MRP systems for job travelers, and inspection software used with CMMs.
  • Experience with secondary finishing operations such as deburring, chamfering, honing or light grinding where applicable.

Soft Skills

  • Exceptional attention to detail and commitment to producing parts within tight tolerances and quality standards.
  • Strong mechanical aptitude with systematic problem-solving and root-cause analysis mindset.
  • Clear verbal and written communication skills to coordinate with engineers, quality inspectors and production planners.
  • Time management and ability to prioritize setups, production runs and urgent reworks under tight deadlines.
  • Team player who can mentor others, accept feedback and contribute to a collaborative shop culture.
  • Initiative and continuous-improvement orientation; comfortable proposing and testing process improvements.
  • Flexibility to work shifts, overtime or weekends when production demand requires.
  • Customer-focus and accountability to ensure deliverables match specifications and on-time expectations.
  • Safety-conscious with demonstrated practice of shop-floor safety, housekeeping and environmental procedures.
  • Adaptability to learn new machinery controls, inspection equipment and process technologies.

Education & Experience

Educational Background

Minimum Education:

  • High School Diploma or equivalent; vocational certificate or trade school in machining is highly desirable.

Preferred Education:

  • Technical diploma or associate degree in Machining Technology, Manufacturing Technology or Mechanical Engineering Technology.

Relevant Fields of Study:

  • Machining / Tool & Die
  • Manufacturing Technology
  • Mechanical Engineering Technology
  • Industrial Maintenance / Mechatronics

Experience Requirements

Typical Experience Range:

  • 2 to 7 years of hands-on machining experience, with at least 2 years of direct gear cutting (hobbing/shaping) experience for production roles.

Preferred:

  • 5+ years of gear manufacturing experience, including setup, inspection and process improvement in a high-mix or high-volume environment; prior experience with AGMA/ISO inspection and CMM operation preferred.
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