The Senior Machinist is a highly skilled, lead-level manufacturing professional responsible for the setup, operation, and maintenance of CNC and manual equipment including vertical milling machines, press brakes, and plasma cutting systems. This role serves as a technical resource for the shop floor, ensuring parts are produced to engineering specifications with a strong emphasis on quality, precision, and on-time delivery. The Senior Machinist is expected to mentor junior machinists, support continuous improvement initiatives, and uphold all applicable quality and safety standards.

Essential Duties & Responsibilities

CNC & Manual Machining

Set up, program (conversational or G-code), operate, and troubleshoot CNC vertical machining centers (VMCs) and manual mills to produce precision components per engineering drawings and tolerances.
Perform first-article inspections and in-process dimensional verification using precision measuring instruments (calipers, micrometers, CMM, height gauges, bore gauges).
Select appropriate tooling, speeds, feeds, and fixturing for efficient and accurate material removal across a variety of metals (steel, aluminum, stainless, titanium, and alloys).
Interpret and work from GD&T-annotated engineering drawings, work orders, and traveler packages.

Press Brake Operations

Set up and operate CNC and manual press brakes to form sheet metal and plate components per specified bend sequences, angles, and tolerances.
Select tooling (punches and dies) and program bending sequences; verify springback compensation and material allowances.
Perform first-piece checks and in-process inspection to ensure dimensional compliance on formed parts.
Maintain die sets and tooling inventory; inspect for wear and report deficiencies.

Plasma Cutting Operations

Set up and operate CNC plasma cutting tables and hand-held plasma systems for profile cutting of ferrous and non-ferrous materials.
Load and nest cut programs; adjust amperage, standoff height, and feed rates to optimize cut quality and minimize HAZ (heat-affected zone).
Inspect cut parts for dimensional accuracy, edge quality, and conformance to drawing specifications.
Perform routine maintenance on plasma cutting equipment including consumable replacement (tips, electrodes, shields) and water table upkeep.

Quality & Documentation

Complete all required production travelers, inspection records, and non-conformance reports (NCRs) in accordance with the quality management system (QMS).
Participate in first-article inspections (FAI), in-process audits, and corrective action activities as needed.
Maintain awareness of and compliance with applicable customer requirements, specifications, and applicable regulatory standards.

Mentorship & Team Leadership

Provide on-the-job training and technical guidance to machinist apprentices, machinists, and setup operators.
Assist with workload planning and job sequencing to support on-time delivery goals.
Communicate effectively with engineering, quality, and production planning to resolve technical issues and disposition non-conforming material.

Safety & 5S / Housekeeping

Follow all company safety policies, OSHA regulations, and PPE requirements at all times.
Maintain work area in accordance with 5S standards; participate in shop floor organization and improvement activities.
Identify and report unsafe conditions, near-misses, and equipment malfunctions to supervision immediately.

Qualifications

Education & Experience

High school diploma or GED required; completion of a formal apprenticeship program, trade school, or associate degree in machining technology strongly preferred.
Minimum 5 years of hands-on machining experience, with at least 2 years in a senior, lead, or setup machinist capacity.
Demonstrated experience operating CNC vertical milling machines, press brakes, and plasma cutting equipment in a production environment.

Technical Skills

Proficient in G-code/M-code programming and conversational CNC controls (Fanuc, Haas, Mazak, or equivalent).
Strong ability to read and interpret engineering drawings, GD&T, blueprints, and work order documentation.
Proficient with precision measurement instruments including micrometers, calipers, height gauges, protractors, and angle finders.
Working knowledge of material properties and machinability of common metals and alloys.
Familiarity with CAM software (Mastercam, Fusion 360, or equivalent) a plus.

Knowledge, Skills & Abilities

Strong problem-solving skills with the ability to identify root cause and implement corrective action on machining and forming defects.
Detail-oriented with a commitment to producing high-quality work within specified tolerances.
Ability to work independently and prioritize tasks in a fast-paced production environment.
Effective verbal and written communication skills; ability to document work clearly and accurately.
Demonstrates a professional, team-oriented attitude and a willingness to mentor and develop others.

Physical Requirements

The following physical demands are representative of those required to successfully perform the essential functions of this position:

Ability to stand, walk, and work on concrete floors for extended periods (up to 10 hours per shift).
Frequently lift and/or move materials, tooling, and fixtures weighing up to 50 lbs; occasionally greater weights with mechanical assist or team lift.
Manual dexterity required for precision hand tool use and machine operation.
Exposure to machine noise, coolant fluids, cutting oils, metal dust, and UV/IR radiation from plasma cutting operations; appropriate PPE required.
Vision requirements: ability to read measuring instruments, engineering drawings, and CNC displays; color distinction may be required.

ND Defense is an equal opportunity employer including disability and veteran.