Individuals in this role oversee the functioning of machinery involved in manufacturing processes or industrial operations. They are responsible for setting up, operating, and monitoring equipment to ensure that it performs according to established specifications. For instance, a machine operator might manage a lathe in a metalworking shop, a printing press in a publishing house, or a packaging machine in a food processing plant.
Effective operation of machinery is crucial for efficient production, quality control, and workplace safety. Historically, manual labor was gradually replaced by automated systems, creating a demand for skilled personnel who could manage and maintain these complex systems. Consequently, proficient oversight of equipment helps to minimize downtime, reduce waste, and maintain consistent product standards, contributing significantly to a company’s profitability and reputation.
The core responsibilities of these professionals encompass a wide range of tasks, including pre-operation inspections, adjustments and calibrations, troubleshooting malfunctions, and performing routine maintenance. This article will further examine the specific skills, daily duties, and necessary qualifications associated with these essential roles.
1. Equipment Setup
Equipment setup represents a foundational aspect of the machine operator’s duties. Proper execution of this initial phase directly influences subsequent operational efficiency, product quality, and overall safety. The process typically involves positioning, calibrating, and adjusting machinery according to established parameters specified in production plans or technical manuals. Failing to adhere to these specifications can result in misaligned products, increased waste, and potential equipment damage. As an example, in a CNC milling operation, incorrect tool installation or workpiece fixturing during setup can lead to dimensional inaccuracies in the final product, requiring rework or scrap.
Furthermore, the setup process often entails loading the correct programs or inputting specific parameters into the machine’s control system. This step is particularly critical in automated production environments where computerized numerical control (CNC) machines are prevalent. Incorrect programming or data entry can lead to unpredictable machine behavior, potentially causing damage to the equipment or injury to personnel. A machine operator in a plastics manufacturing plant, for example, must precisely configure the injection molding machine’s temperature, pressure, and cycle time during setup to ensure the production of consistent and structurally sound components.
In summary, the equipment setup phase is not merely a preliminary task but an integral component of the entire machine operation process. Precise execution of this phase is directly correlated with achieving production goals, maintaining product quality, and ensuring a safe working environment. The operator’s understanding of equipment manuals, programming interfaces, and material properties is paramount for successful setup and subsequent operation.
2. Process Monitoring
Process monitoring is an indispensable component of machine operation, serving as a continuous feedback loop to ensure optimal performance, quality adherence, and early detection of potential issues. It is the active and sustained observation of machine functions during operation, allowing for real-time adjustments and preventative interventions.
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Visual Inspection
Visual inspection is a fundamental aspect of process monitoring. Machine operators regularly observe the machine’s physical operation, watching for unusual noises, vibrations, or visual anomalies. For example, an operator of a textile loom might observe the tension of the threads or the movement of the shuttle. Deviations from the norm can indicate mechanical wear, misalignment, or potential component failure. Detecting these issues early prevents further damage and minimizes downtime.
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Gauge and Meter Readings
Modern machinery is often equipped with gauges, meters, and digital displays that provide critical data on performance metrics such as pressure, temperature, speed, and power consumption. Machine operators are trained to interpret these readings and recognize deviations from established parameters. For example, an operator of a hydraulic press might monitor pressure readings to ensure consistent force application. Drastic fluctuations could signal a leak, pump malfunction, or other hydraulic system issues.
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Material Flow and Quality Checks
Process monitoring extends to the examination of the materials being processed. Operators routinely assess material flow to ensure a consistent feed rate and identify potential blockages or disruptions. Furthermore, quality checks are performed at various stages of the process to verify that the output meets specified standards. In a bottling plant, an operator might monitor the flow of liquid into bottles and inspect filled containers for proper fill levels and seal integrity. This vigilance helps prevent defective products from reaching consumers.
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Alarm System Response
Sophisticated machinery often incorporates alarm systems that trigger warnings when predefined thresholds are exceeded. Machine operators must be capable of interpreting alarm codes, identifying the underlying cause of the alarm, and implementing corrective actions. For instance, a CNC machine might trigger an alarm if the spindle temperature rises above a safe operating level. The operator would then need to investigate the cooling system, lubrication levels, or cutting parameters to resolve the issue and prevent damage to the machine or workpiece.
These facets of process monitoring are intricately linked to the core responsibilities of machine operators. By diligently observing machine performance, interpreting data, and responding to anomalies, operators play a crucial role in maintaining production efficiency, ensuring product quality, and preventing costly equipment failures. Effective process monitoring transforms operators from passive observers to active participants in the manufacturing process, contributing significantly to overall operational success.
3. Quality Control
Quality control is intrinsically linked to the responsibilities of machine operators, forming a crucial component of their daily tasks and overall contribution to the production process. The operator’s role in maintaining product standards directly influences the final output and overall efficiency of manufacturing operations. Deviations from established quality parameters can lead to increased waste, production delays, and potential damage to equipment. For example, in a pharmaceutical manufacturing setting, a machine operator monitoring capsule filling equipment must ensure consistent fill weights and proper sealing to comply with stringent quality regulations. Failure to do so could result in product recalls and significant financial repercussions.
Practical applications of quality control in a machine operator’s workflow are numerous and varied. Operators frequently perform visual inspections of finished products, checking for defects, inconsistencies, or deviations from specifications. They also employ measuring instruments such as calipers, micrometers, and gauges to verify dimensional accuracy. In addition, operators often collect samples for laboratory testing or conduct in-process testing to monitor critical parameters such as temperature, pressure, or viscosity. These activities enable the timely identification and correction of process variations before they lead to widespread quality issues. Consider a machine operator in a paper mill. They monitor the paper thickness, weight, and tensile strength, making adjustments to the machine to maintain consistent paper quality and prevent variations that could lead to paper breaks or uneven printing.
In summary, the integration of quality control into the machine operator’s duties is paramount for ensuring product integrity, minimizing waste, and maximizing efficiency. Effective implementation of quality control measures by machine operators presents challenges, including the need for ongoing training, accurate measurement tools, and adherence to strict protocols. However, a thorough understanding of the connection between machine operation and quality control is essential for success in modern manufacturing environments and contributes significantly to a company’s competitive advantage.
4. Troubleshooting
Troubleshooting constitutes a critical function within the purview of machine operators. Machine malfunctions, process deviations, and unexpected downtime events necessitate immediate attention and resolution. Machine operators are often the first line of defense when equipment irregularities arise, requiring them to diagnose the root cause of the problem and implement corrective measures. The ability to effectively troubleshoot directly impacts production efficiency, minimizes equipment damage, and contributes to workplace safety. A disruption in the proper operation of equipment frequently stems from a mechanical failure, electrical issue, or programming error; for instance, a printing press operator encountering blurred print might troubleshoot ink viscosity, roller alignment, or the digital file being used for printing.
The troubleshooting process often begins with careful observation and data collection. Machine operators analyze error codes, monitor machine parameters, and assess the physical state of the equipment. This diagnostic phase helps to narrow down the potential causes of the malfunction. Based on their observations, operators then implement a series of corrective actions. This might involve replacing worn parts, adjusting machine settings, or re-programming the machines control system. Consider a scenario involving a packaging machine operator tasked with resolving intermittent sealing failures on food product pouches; the operator may first inspect the sealing jaws for contamination or damage, then check temperature settings, and ultimately calibrate the sealing pressure to re-establish consistent and airtight seals.
Ultimately, troubleshooting skills are indispensable for machine operators, contributing directly to operational resilience and productivity. While certain complex malfunctions may require the expertise of specialized technicians, the operator’s ability to identify and resolve common issues swiftly prevents extended downtime. Ongoing training, adherence to safety protocols, and a thorough understanding of machine mechanics are essential for developing effective troubleshooting capabilities within the operator role. The operator who can accurately diagnose and remedy machine issues plays a pivotal role in optimizing production and maintaining the overall health of manufacturing operations.
5. Routine Maintenance
Routine maintenance forms an integral component of the responsibilities assumed by machine operators. The consistent performance and longevity of industrial machinery depend significantly on proactive measures undertaken to prevent failures and optimize operational efficiency. Machine operators, as the individuals directly involved with the daily operation of equipment, are often charged with performing basic maintenance tasks, which range from lubrication and cleaning to inspecting wear-prone components and replacing minor parts. Failure to adhere to scheduled maintenance protocols can result in accelerated equipment degradation, unexpected downtime, and increased repair costs. For instance, in the case of a textile weaving machine, a machine operator’s daily tasks include lubricating moving parts, checking thread guides for wear, and cleaning accumulated lint. Neglecting these tasks can lead to increased friction, thread breakage, and compromised fabric quality.
The practical applications of routine maintenance are diverse and contribute directly to the reliable functioning of manufacturing processes. Machine operators may be responsible for monitoring fluid levels (oil, coolant, hydraulic fluids), replacing filters, tightening fasteners, and verifying the calibration of sensors. Consistent monitoring of these parameters helps detect early signs of malfunction or potential issues, allowing for timely intervention and preventing more significant equipment failures. Consider the example of a plastic injection molding machine where a machine operator is tasked with routinely inspecting the cooling system for leaks, cleaning the mold surfaces, and verifying the proper functioning of the ejection system. Ignoring such routine checks can lead to overheating, product defects, and reduced production output.
In summary, the integration of routine maintenance into the machine operator’s workflow is essential for ensuring operational efficiency, minimizing equipment downtime, and extending the lifespan of machinery. Challenges arise in balancing production demands with the time required for thorough maintenance, necessitating careful scheduling and efficient execution. Understanding the direct connection between preventative maintenance and the sustained operation of equipment is critical for machine operators and contributes significantly to the overall success of manufacturing and industrial enterprises. The value of this proactive approach directly impacts profitability, product quality, and workplace safety.
6. Safety Compliance
Safety compliance forms an undeniable and paramount aspect of machine operation. A machine operator’s duties are inextricably linked to adherence to established safety protocols and regulations. These measures aim to mitigate risks associated with operating heavy machinery, ensuring the well-being of the operator and the surrounding work environment. Neglecting safety compliance can result in accidents, injuries, equipment damage, and potential legal ramifications.
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Personal Protective Equipment (PPE)
Machine operators are routinely required to utilize personal protective equipment, including safety glasses, gloves, hearing protection, and appropriate footwear. The specific PPE requirements vary depending on the machinery being operated and the potential hazards involved. For example, an operator of a metal stamping press must wear safety glasses to protect against flying debris and hearing protection to mitigate noise exposure. Adherence to PPE guidelines is essential for minimizing the risk of injury and ensuring a safe working environment.
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Lockout/Tagout Procedures
Lockout/tagout (LOTO) procedures are implemented during maintenance, repair, or setup operations to prevent the accidental activation of machinery. These procedures involve isolating energy sources, such as electrical power, hydraulic pressure, or pneumatic lines, and attaching locks and tags to indicate that the equipment is de-energized. A machine operator performing maintenance on a conveyor system, for instance, must follow LOTO procedures to prevent the conveyor from unexpectedly starting, potentially causing serious injury. Strict adherence to LOTO protocols is crucial for preventing accidents and ensuring operator safety during equipment servicing.
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Emergency Stop Mechanisms
Machine operators must be thoroughly familiar with the location and operation of emergency stop mechanisms on the machinery they operate. These mechanisms provide a rapid means of shutting down the equipment in the event of an emergency, such as a machine malfunction or an operator entanglement. An operator working with a robotic arm, for example, should know how to immediately stop the robot’s movements in the event of an unexpected collision. Regular drills and training on the use of emergency stop mechanisms are essential for ensuring a swift and effective response to critical situations.
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Hazard Communication
Machine operators must be aware of the potential hazards associated with the materials and processes used in their work environment. Hazard communication programs, including safety data sheets (SDS), provide information on the properties, risks, and safe handling procedures for chemicals and other hazardous substances. An operator using cutting fluids in a machining operation, for example, should understand the potential skin irritation or respiratory hazards associated with the fluid and follow appropriate handling and disposal procedures. A thorough understanding of hazard communication principles is essential for minimizing the risk of exposure to hazardous substances and ensuring a safe working environment.
These facets of safety compliance underscore the critical role of machine operators in maintaining a safe and productive work environment. Through consistent adherence to safety protocols, diligent use of PPE, and a thorough understanding of emergency procedures, machine operators contribute significantly to minimizing risks and preventing accidents. The commitment to safety not only protects the well-being of operators but also enhances overall operational efficiency and reduces the potential for costly disruptions. Thus, safety compliance is not merely a regulatory requirement, but a fundamental principle of responsible machine operation.
7. Material Handling
Material handling forms a critical and often integrated component of the duties performed by machine operators. The efficient and safe movement of raw materials, work-in-process inventory, and finished goods directly impacts production throughput, quality control, and workplace safety. Inadequate material handling practices can lead to production bottlenecks, product damage, increased waste, and potential injuries. The cause-and-effect relationship is evident: proficient material handling enables a smooth and uninterrupted flow of materials to and from machinery, while inefficient handling introduces delays, inefficiencies, and potential hazards. For instance, a machine operator responsible for a paper converting machine must ensure a consistent supply of paper rolls to prevent downtime. Improper loading or handling of these rolls can damage the material or disrupt the production process, leading to significant losses.
The integration of material handling into a machine operator’s responsibilities requires a comprehensive understanding of lifting techniques, equipment operation (e.g., forklifts, pallet jacks), and adherence to safety protocols. Machine operators may be responsible for loading raw materials into machinery, unloading finished products, and transporting materials between workstations. In a metal fabrication shop, a machine operator might use an overhead crane to load heavy steel plates onto a cutting machine and subsequently move the cut pieces to the next stage of production. Accurate material placement and securement are paramount to prevent accidents and material damage. Furthermore, optimizing material flow within the workspace enhances efficiency and minimizes unnecessary movements.
In conclusion, effective material handling is an indispensable skill for machine operators, directly influencing production efficiency, product quality, and workplace safety. Challenges associated with material handling include lifting heavy objects, navigating confined spaces, and coordinating with other team members. However, proper training, adherence to safety guidelines, and the implementation of ergonomic practices can mitigate these challenges and ensure the safe and efficient movement of materials within the manufacturing environment. A thorough understanding of the interplay between material handling and machine operation is crucial for optimizing production processes and achieving operational excellence.
8. Production Output
The volume and quality of production output are directly correlated with the performance of machine operators. As the primary individuals responsible for operating and maintaining machinery, their actions directly impact the efficiency and effectiveness of the manufacturing process. The operator’s ability to set up equipment correctly, monitor its operation diligently, and troubleshoot malfunctions swiftly contributes significantly to achieving optimal production levels. Substandard performance in these areas invariably leads to reduced output, increased waste, and potential delays in fulfilling orders. For example, in a bottling plant, if the machine operator fails to properly calibrate the filling machine, the resulting underfilled or overfilled bottles directly diminish the total number of saleable units produced per hour.
Effective machine operation involves not only maximizing the speed of production but also maintaining consistent product quality. Operators must carefully monitor process parameters, such as temperature, pressure, and speed, to ensure that the output meets established standards. Quality control checks implemented by the operator throughout the production cycle serve as a crucial mechanism for identifying and correcting deviations that could negatively affect the finished product. Consider a CNC milling machine operator who must maintain precise tolerances on machined parts. Any deviation from the specified dimensions, resulting from improper setup or machine wear, will lead to rejected parts and a decrease in usable production output. A skilled operator proactively identifies and addresses these issues to minimize waste and maintain consistent quality.
In summary, machine operators play a central role in determining the overall production output of a manufacturing facility. Their competence in equipment setup, process monitoring, troubleshooting, and quality control directly influences both the quantity and quality of goods produced. While external factors such as raw material availability and market demand also contribute to production levels, the machine operator’s skill and diligence remain critical determinants of achieving optimal operational efficiency and meeting production targets.
9. Data Recording
Precise data recording constitutes an indispensable function interwoven with the activities of machine operators. The meticulous documentation of operational parameters, production metrics, and maintenance activities serves as a foundational element for process optimization, quality control, and informed decision-making within manufacturing environments. Accurate and consistent data entry enables the identification of trends, the prediction of potential equipment failures, and the implementation of corrective actions to improve overall efficiency.
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Production Statistics
Machine operators are often responsible for recording production statistics such as the number of units produced, cycle times, and material consumption rates. This data provides a real-time snapshot of production efficiency and helps identify bottlenecks or areas for improvement. For instance, a machine operator in a packaging plant might track the number of boxes filled per hour, providing valuable insights into machine performance and potential causes for slowdowns. Analyzing this information enables managers to optimize production schedules and allocate resources effectively.
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Quality Control Metrics
Data pertaining to quality control measures is also routinely captured by machine operators. This includes recording the number of rejected units, defect types, and measurements obtained during quality inspections. This information provides valuable feedback on process stability and helps identify root causes of quality issues. As an example, a machine operator in a metalworking shop might record the dimensions of machined parts, identifying instances where tolerances are not met and enabling timely adjustments to machine settings. This proactive approach minimizes waste and ensures consistent product quality.
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Maintenance Logs
Machine operators typically maintain detailed logs of maintenance activities, including routine inspections, repairs, and component replacements. This information is crucial for tracking equipment performance, predicting future maintenance needs, and optimizing maintenance schedules. Consider a scenario in which a machine operator records the dates of lubrication, filter changes, and belt replacements for a conveyor system. Analyzing this data can reveal patterns of wear and tear, enabling proactive maintenance and preventing costly breakdowns. Accurate maintenance logs contribute to extended equipment lifespan and reduced downtime.
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Downtime Events
Detailed records of downtime events, including the time, duration, and cause of machine stoppages, are essential for identifying and addressing recurring problems. Machine operators are often tasked with documenting these events, providing valuable information for engineers and maintenance personnel. For instance, if a machine operator reports frequent stoppages due to sensor failures, this data can prompt an investigation into the sensor type, installation, or environmental conditions. Analyzing downtime records helps pinpoint the root causes of disruptions and enables the implementation of effective solutions to minimize future downtime.
The practice of diligent data recording by machine operators extends beyond mere compliance with documentation requirements. It provides a crucial feedback loop for continuous improvement, enabling data-driven decisions that optimize production processes, enhance product quality, and reduce operational costs. The data collected serves as a valuable resource for identifying areas where training, equipment upgrades, or process modifications can lead to significant gains in efficiency and overall operational effectiveness. Accurate data recording transforms operators from passive participants to active contributors in the ongoing pursuit of manufacturing excellence.
Frequently Asked Questions About Machine Operation
The following questions address common concerns and provide concise answers regarding the key aspects of machine operation, offering clarity on the responsibilities, skills, and challenges inherent in this role.
Question 1: What fundamental skills are required to succeed as a machine operator?
Successful machine operators require a blend of technical proficiency and practical aptitude. Essential skills include mechanical aptitude, the ability to interpret technical manuals, basic mathematical skills, and proficiency in using measuring instruments. Furthermore, strong problem-solving skills and the capacity to work independently and as part of a team are critical for success.
Question 2: How does a machine operator contribute to quality control in a manufacturing setting?
Machine operators play a pivotal role in quality control by consistently monitoring process parameters, conducting visual inspections of finished products, and performing in-process testing. They utilize measuring instruments to verify dimensional accuracy and identify deviations from specifications, enabling timely corrective actions to prevent widespread quality issues.
Question 3: What safety measures are essential for machine operators to observe during their work?
Adherence to strict safety protocols is paramount for machine operators. This includes consistently using personal protective equipment (PPE), following lockout/tagout procedures during maintenance, being familiar with emergency stop mechanisms, and understanding hazard communication principles related to materials and processes used.
Question 4: What is the significance of data recording in machine operation?
Precise data recording is vital for tracking production statistics, quality control metrics, maintenance activities, and downtime events. This data provides valuable insights into process stability, equipment performance, and potential areas for improvement, enabling data-driven decisions to optimize manufacturing processes.
Question 5: How does routine maintenance performed by machine operators impact equipment lifespan and operational efficiency?
Routine maintenance, including lubrication, cleaning, component inspection, and minor part replacements, is crucial for preventing equipment failures, minimizing downtime, and extending the lifespan of machinery. Consistent maintenance practices optimize equipment performance and contribute significantly to operational efficiency.
Question 6: What role does material handling play in the overall responsibilities of a machine operator?
Efficient and safe material handling is an integral part of a machine operator’s duties. This involves the proper movement of raw materials, work-in-process inventory, and finished goods, which directly impacts production throughput, quality control, and workplace safety. Skillful material handling minimizes bottlenecks, prevents material damage, and enhances overall operational efficiency.
In summation, comprehending the diverse aspects of machine operation, from technical skills and safety compliance to quality control and data recording, provides a comprehensive perspective on the demands and importance of this role in modern manufacturing.
The next section of this article will explore career pathways and educational requirements associated with machine operation positions.
Essential Guidance for Effective Machine Operation
The subsequent recommendations serve as a practical guide for enhancing performance and maximizing efficiency within the realm of machine operation. These suggestions are formulated to address critical aspects of the role, emphasizing precision, safety, and proactive engagement.
Tip 1: Prioritize Pre-Operational Inspections. Diligent inspection of machinery prior to commencing operations is paramount. This includes verifying fluid levels, checking for loose components, and ensuring proper calibration of sensors. Neglecting these checks can lead to equipment malfunctions and compromised output quality.
Tip 2: Maintain Continuous Process Monitoring. Active and sustained observation of machine functions during operation is crucial. Monitoring gauges, meters, and visual cues allows for the early detection of deviations from established parameters, enabling timely interventions and preventing costly equipment failures.
Tip 3: Implement Stringent Quality Control Measures. Integrate quality control checks throughout the production process. Regularly inspect finished products for defects, utilize measuring instruments to verify dimensional accuracy, and promptly address any deviations from specifications to ensure consistent product quality.
Tip 4: Develop Proficiency in Troubleshooting. Acquire a thorough understanding of machine mechanics and control systems to facilitate rapid diagnosis and resolution of malfunctions. Analyze error codes, monitor machine parameters, and implement corrective actions swiftly to minimize downtime and prevent equipment damage.
Tip 5: Adhere to Rigorous Safety Protocols. Compliance with established safety protocols is non-negotiable. Consistently utilize personal protective equipment (PPE), follow lockout/tagout procedures during maintenance, and maintain a comprehensive understanding of emergency stop mechanisms to ensure a safe working environment.
Tip 6: Cultivate Detailed Data Recording Practices. Meticulously document operational parameters, production metrics, and maintenance activities. Accurate data entry enables the identification of trends, the prediction of potential equipment failures, and the implementation of corrective actions to optimize overall efficiency.
Tip 7: Engage in Proactive Routine Maintenance. Regularly perform scheduled maintenance tasks, including lubrication, cleaning, component inspection, and minor part replacements. This proactive approach helps prevent equipment failures, extends machinery lifespan, and optimizes operational efficiency.
Implementing these guidelines enhances operational effectiveness, minimizes risks, and promotes a culture of excellence within machine operation environments. These practices contribute to increased productivity, improved product quality, and a safer, more efficient workplace.
The subsequent segment of this document will focus on future trends impacting the machine operation field, including technological advancements and evolving skill requirements.
Conclusion
This article has explored the multifaceted responsibilities inherent in the role of machine operators. It has underscored the critical importance of their contributions to manufacturing and industrial processes. From equipment setup and process monitoring to quality control, troubleshooting, routine maintenance, and safety compliance, these professionals are essential for maintaining efficient operations and producing quality goods. The analysis of material handling, production output, and data recording has further illuminated the breadth and depth of their impact.
As technology continues to evolve, so too will the demands placed on individuals performing these functions. Continuous learning and adaptation will be crucial for success in this field. Therefore, a commitment to ongoing training and a dedication to mastering new skills are essential for navigating the future landscape of machine operation and contributing to the ongoing advancement of manufacturing and industrial sectors. The continued focus on safety, efficiency, and quality will remain paramount, ensuring the continued relevance and importance of skilled machine operators in the global economy.
