Gear Grinder A

Gear Grinder

Flender is a leading global supplier for mechanical drive systems and has the reputation for highest performance, innovation, quality, and reliability of mechanical components for 125 years.

We're now hiring a talented Gear Grinder for our team in Elgin, IL on a full-time basis. If you're eager for your next challenge, Flender is a great place to grow your career.

Job Summary:

This position typically requires 8+ years of experience in precision grinding or a similar field and 3+ years specifically in profile grinding of gears or gear-related components. Working with minimal technical supervision, the Skilled Gear Grinder performs complex set-ups and grinding operations on profile gear grinding machines to produce and finish gears and gear components to very close tolerances and stringent quality requirements.

The employee independently:

• Interprets blueprints, process sheets, and work instructions
• Selects and mounts workholding, grinding wheels, and dressing tools
• Programs/edits CNC profile grinding cycles as required
• Determines operation sequences and grinding strategies
• Performs in-process inspection and makes necessary corrections to maintain tolerances

The Skilled Gear Grinder uses all required precision measuring equipment, and understands gear geometry (e.g., involute profile, lead, pitch)

At this level the employee acts as a technical resource for less experienced grinders and machinists, provides on-the-job training to new employees, actively participates in process improvements, and has a proven track record of improvement submissions.

May perform other duties as assigned by supervisor. May be required to oversee quality, workmanship and training of fellow team members and, as assigned, perform the role of lead person.

Job Responsibilities:

Essential Job Functions

Set-Up & Operation – Profile Gear Grinding Machines

• Load, clamp, align, and center gear workpieces and mandrels.
• Set up and operate assigned profile gear grinding machines (e.g., Niles, Pfauter, Liebherr, Höfler, or equivalent).
• Adjust fixturing, machine offsets, and process parameters to achieve required tolerances and surface finish.

Programming and Process Definition

• Program or modify CNC profile grinding programs as needed to meet drawing and process requirements.
• Determine and optimize operation sequences for profile, lead, and root grinding.
• Select and set dressing parameters for grinding wheels and form rolls.

Inspection, Measurement & Documentation

• Perform in-process and final inspections using appropriate measuring equipment (e.g., gear measuring centers, lead/profile testers, micrometers, calipers, indicators, surface roughness gauges).
• Read and interpret gear inspection charts and make corrections to maintain tolerances.
• Prepare and maintain productivity, capacity, and quality figures according to given schemes and work standards.

Troubleshooting & Problem Solving

• Independently analyze grinding problems (burn, chatter, profile/lead deviations, taper, runout, size variation).
• Implement corrective actions related to wheel selection, dressing, coolant, feeds/speeds, and clamping methods.
• Analyze error incidence and support root-cause analysis and corrective actions.

Machine Care, Maintenance & Housekeeping

• Monitor service intervals, perform assigned preventive maintenance, and carry out cleaning tasks to keep machines in good working order.
• Respond promptly to machine alarms and minor mechanical issues and coordinate with maintenance as required.
• Maintain a clean and orderly work area in compliance with 5S standards.

Barkhausen Noise

• Operate Barkhausen noise measurement equipment to detect grinding burn and surface damage on ground parts as required by the control plan. Training on the Barkhausen device and evaluation criteria will be provided.

Training & Support of Others

• Provide structured training and guidance for new grinders and machinists on profile grinding processes, safety, and quality requirements.
• Share best practices and act as a subject matter expert for gear grinding operations.

Cross-Training and Flexibility

• As required, operate a secondary machine (e.g., gear inspection equipment, hard turning, or other grinding operations) within training and capability.
• Machine training assignments are determined by the supervisor based on the cross-training matrix and business needs.

Communication & Teamwork

• Maintain good communication and professional behavior with supervisors, quality personnel, maintenance, and fellow team members.
• Report deviations, nonconformances, and safety concerns promptly and constructively.

Production Planning & Performance

• Ensure targeted dates, capacities, and productivity requirements are met, according to route sheets and supervisor direction.
• Support continuous improvement in throughput, set-up time, and first-pass yield.

Safety & Compliance

• Operate cranes, fork trucks, and rigging (chains, shackles, straps) only when trained and authorized, and in compliance with plant SOPs.
• Follow the SOP for Inspection of Lifting Slings, Chains, and Shackles when using rigging equipment.
• Adhere to all EH&S, ISO, and internal quality requirements and work standards.

Continuous Improvement Participation

• Maintain a proven record of improvement submissions or equivalent improvement activities, including cost-saving and safety-related ideas.
• Actively participate in problem-solving teams and improvement workshops.

Marginal Job Functions

Initiates orders for tools, fixtures, grinding wheels, dressing tools, and supplies as needed. Performs general cleaning and housekeeping to keep the department as clean and organized as possible.

Necessary Prior Experience

Nature & Type of Experience Required

• Experience as a CNC or conventional grinder, gear machinist, or similar precision machining role.
• Demonstrated experience in profile grinding of gears or gear-type components, including reading gear drawings and inspection records.
• Experience working with alloy and case-hardened steels, including awareness of grinding burn and microstructural damage.

Amount of Experience (Typical)

• Precision or CNC grinding / gear machining: 8+ years
• Profile gear grinding (primary process): 3+ years

Educational Requirements

• High school diploma or equivalent required.
• Completion of an apprenticeship, vocational training, or technical degree in machining, toolmaking, or related field preferred.

Physical Demands Analysis

• Standing Stationary: C
• Moving About: C
• Sitting: O

Lifting (Push/Pull Stationary)

• Up to 10 lbs.: O
• 10 to 20 lbs.: O
• 20 to 50 lbs.: O

Carrying (Push/Pull Moving About)

• Up to 10 lbs.: O
• 10 to 20 lbs.: O
• 20 to 50 lbs.: O
• Climbing: O
• Balancing: O
• Stooping: O
• Kneeling: O
• Crouching: F
• Reaching: C
• Handling: C
• Fingering: F
• Talking: F
• Hearing: C

Visual Requirements

• Near Vision: C
• Far Vision: O
• Depth Perception