Manufacturing & ProductionMetal, machinery and related trades workersISCO 7223
spark erosion machine operator
Spark erosion machine operators set up and tend spark erosion machines designed to cut excess material from a metal workpiece by the use of electrical discharges, or sparks, caused by electric voltage and separated by a dielectric liquid, which removes pieces of metal from the electrodes. These applications can involve transmission and optical microscopy.
About spark erosion machine operator
As a spark erosion machine operator, you will work with precision electrical discharge machinery to shape and refine metal workpieces with extraordinary accuracy. Your daily responsibilities include setting up complex spark erosion machines, monitoring their operation, and troubleshooting issues to ensure consistently high-quality output. You'll work with various metal types, applying electrical discharge technology to remove excess material through controlled sparking processes separated by dielectric liquids. This role requires precision, attention to detail, and technical expertise—you'll operate measuring equipment, interpret technical specifications, monitor automated processes, and manage quality standards throughout production. Spark erosion is a critical process in manufacturing, particularly in industries such as automotive, aerospace, tooling, and precision engineering where tolerances are measured in micrometers. The Polish manufacturing sector, especially in Silesia and Greater Poland, has strong demand for skilled spark erosion operators as companies continue to invest in advanced precision manufacturing capabilities.
Key Work Functions
Core areas of responsibility for a spark erosion machine operator.
1
Set up and configure spark erosion machines
- Install workpieces and electrodes according to specifications and technical drawings
- Configure machine parameters including voltage, discharge frequency, and dielectric liquid circulation
- Program and adjust controller settings for specific erosion profiles
- Test machine functionality before commencing production runs
2
Monitor and operate spark erosion processes
- Supervise automated machine operation and electrical discharge processes
- Monitor machine performance, dielectric liquid levels, and electrode wear
- Maintain accurate records of production parameters and machine settings
- Track production progress and adjust settings to maintain quality standards
3
Quality control and inspection
- Operate precision measuring equipment including micrometers, calipers, and optical microscopy tools
- Inspect finished workpieces against dimensional specifications and quality standards
- Identify and remove inadequate or defective workpieces from production
- Document quality measurements and maintain quality assurance records
4
Troubleshoot and maintain equipment
- Identify and troubleshoot machine malfunctions and performance issues
- Perform routine maintenance including electrode replacement and dielectric liquid servicing
- Consult technical resources and documentation to resolve operational issues
- Request technical support from maintenance specialists when required
5
Material handling and waste management
- Supply machines with metal blanks and raw materials according to production schedules
- Remove processed workpieces from machines safely after erosion is complete
- Dispose of cutting waste material and contaminated dielectric liquid according to regulations
- Apply cross-reference tools and product identification systems to track workpieces
European Skills Framework
Skills and knowledge areas required for this occupation based on European classification.
Essential (15)
electrical dischargeelectrical dischargeThe qualities and applications of electrical discharge, including voltage and electrodes.types of metaltypes of metalQualities, specifications, applications and reactions to different fabricating processes of various types of metal, such as steel, aluminium, brass, copper and others.quality standardsquality standardsThe national and international requirements, specifications and guidelines to ensure that products, services and processes are of good quality and fit for purpose.metal eroding technologymetal eroding technologyThe various eroding technology and techniques, automated or otherwise, such as electrical discharge machining, die sinking, wire eroding and others.remove inadequate workpiecesremove inadequate workpiecesEvaluate which deficient processed workpieces do not meet the set-up standard and should be removed and sort the waste according to regulations.troubleshoottroubleshootIdentify operating problems, decide what to do about it and report accordingly.tend spark erosion machinetend spark erosion machineMonitor and operate a spark erosion machine according to regulations.remove processed workpieceremove processed workpieceRemove individual workpieces after processing, from the manufacturing machine or the machine tool. In case of a conveyor belt this involves quick, continuous movement.operate precision measuring equipmentoperate precision measuring equipmentMeasure the size of a processed part when checking and marking it to check if it is up to standard by use of two and three dimensional precision measuring equipment such as a caliper, a micrometer, an...dispose of cutting waste materialdispose of cutting waste materialDispose of possibly hazardous waste material created in the cutting process, such as swarf, scrap and slugs, sort according to regulations, and clean up workplace.apply cross-reference tools for product identificationapply cross-reference tools for product identificationEmploy cross-reference tools and programmes, listing file names and line numbers, to identify part numbers, descriptions, and the vendor as source of origin.monitor automated machinesmonitor automated machinesContinuously check up on the automated machine's set-up and execution or make regular control rounds. If necessary, record and interpret data on the operating conditions of installations and equipment...supply machinesupply machineEnsure the machine is fed the necessary and adequate materials and control the placement or automatic feed and retrieval of work pieces in the machines or machine tools on the production line.consult technical resourcesconsult technical resourcesRead and interpret technical resources such as digital or paper drawings and adjustment data in order to properly set up a machine or working tool, or to assemble mechanical equipment.set up the controller of a machineset up the controller of a machineSet up and give commands to a machine by dispatching the appropriate data and input into the (computer) controller corresponding with the desired processed product.
Optional (34)
non-ferrous metal processingnon-ferrous metal processingVarious processing methods on non-ferrous metals and alloys such as copper, zinc and aluminium.statistical process controlstatistical process controlMethod of quality control that uses statistics to monitor processes.cutting technologiescutting technologiesThe variety of cutting technologies, such as software or mechanics, guiding cutting processes through lasering, sawing, milling etc.manufacturing of cutlerymanufacturing of cutleryThe manufacture of different cutlery items, such as forks, spoons, knives, razors or scissors.quality and cycle time optimisationquality and cycle time optimisationThe most optimal rotation or cycle time and over-all quality of a tool or a machine's processes.electrical engineeringelectrical engineeringThe field of engineering that deals with the study and application of electricity, electronics, and electromagnetism.ferrous metal processingferrous metal processingVarious processing methods on iron and iron-containing alloys such as steel, stainless steel and pig iron.manufacturing of metal household articlesmanufacturing of metal household articlesThe manufacture of flatware , hollowware , dinnerware and other non-electrical utensils for use at the table or in the kitchen.manufacture of small metal partsmanufacture of small metal partsThe manufacture of metal cable, plaited bands and other articles of that type, uninsulated or insulated cable not capable of being used as a conductor of electricity, coated or cored wire as well as b...manufacturing of metal containersmanufacturing of metal containersThe manufacture of reservoirs, tanks and similar containers of metal, of types normally installed as fixtures for storage or manufacturing use. The manufacture of metal containers for compressed or li...types of metal manufacturing processestypes of metal manufacturing processesMetal processes linked to the different types of metal, such as casting processes, heat treatment processes, repair processes and other metal manufacturing processes.manufacturing of door furniture from metalmanufacturing of door furniture from metalThe manufacture of metal items that can be attached to a door in order to support its function and appearance. The manufacture of padlocks, locks, keys, hinges and the like, and hardware for buildings...manufacturing of light metal packagingmanufacturing of light metal packagingThe manufacture of tins and cans for food products, collapsible tubes and boxes, and of metallic closures.chemistrychemistryThe composition, structure, and properties of substances and the processes and transformations that they undergo; the uses of different chemicals and their interactions, production techniques, risk fa...manufacturing of weapons and ammunitionmanufacturing of weapons and ammunitionThe manufacture of heavy weapons (artillery, mobile guns, rocket launchers, torpedo tubes, heavy machine guns), small arms (revolvers, shotguns, light machine guns), air or gas guns and pistols, and w...manufacturing of toolsmanufacturing of toolsThe manufacture of knives and cutting blades for machines or for mechanical appliances, hand tools such as pliers, screwdrivers etc. The manufacture of non-power-driven agricultural hand tools, saws a...manufacturing of steam generatorsmanufacturing of steam generatorsThe manufacture of steam or other vapour generators, the manufacture of auxiliary plant for use with steam generators: condensers, economisers, superheaters, steam collectors and accumulators. The man...inspect quality of productsinspect quality of productsUse various techniques to ensure the product quality is respecting the quality standards and specifications. Oversee defects, packaging and sendbacks of products to different production departments.perform product testingperform product testingTest processed workpieces or products for basic faults.monitor stock levelmonitor stock levelEvaluate how much stock is used and determine what should be ordered.perform test runperform test runPerform tests putting a system, machine, tool or other equipment through a series of actions under actual operating conditions in order to assess its reliability and suitability to realise its tasks, ...ensure public safety and securityensure public safety and securityImplement the relevant procedures, strategies and use the proper equipment to promote local or national security activities for the protection of data, people, institutions, and property.read standard blueprintsread standard blueprintsRead and comprehend standard blueprints, machine, and process drawings.ensure equipment availabilityensure equipment availabilityEnsure that the necessary equipment is provided, ready and available for use before start of procedures.use CAM softwareuse CAM softwareUse computer-aided manufacturing (CAM) programmes to control machinery and machine tools in the creation, modification, analysis, or optimisation as part of the manufacturing processes of workpieces.advise on machinery malfunctionsadvise on machinery malfunctionsOffer advice to service technicians in case of machinery malfunctions and other technical repair tasks.mark processed workpiecemark processed workpieceInspect and mark parts of the workpiece to indicate how they will fit into the finished product.maintain mechanical equipmentmaintain mechanical equipmentObserve and listen to machinery operation to detect malfunction. Service, repair, adjust, and test machines, parts, and equipment that operate primarily on the basis of mechanical principles. Maintain...program a CNC controllerprogram a CNC controllerSet up the desired product design in the CNC controller of the CNC machine for product manufacturing.replace machinesreplace machinesEvaluate when to invest in replacing machines or machine tools and take the necessary actions.keep records of work progresskeep records of work progressMaintain records of the progress of the work including time, defects, malfunctions, etc.interpret geometric dimensions and tolerancesinterpret geometric dimensions and tolerancesUnderstand and assess the models and symbolic language of Geometric Dimensioning and Tolerancing (GD&T) systems indicating engineering tolerances.apply control process statistical methodsapply control process statistical methodsApply statistical methods from Design of Experiments (DOE) and Statistical Process Control (SPC) in order to control manufacturing processes.record production data for quality controlrecord production data for quality controlKeep records of the machine's faults, interventions and irregularities for quality control.
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Quick Facts
ISCO GroupMetal, machinery and related trades workers
Essential Skills15
Core Skills0