Machine Operator vs. Intelligent Machine Operator

• A (Machine) Operator is anyone who uses a System to perform a Task/Operation. Examples include:

  • A Landscaper operating a Lawnmower to Cut Grass

  • A Machinist operating a CNC Mill to Machine Fishing Lure Molds

  • An X-Ray Technician operating an X-Ray Machine to Take Images of a Patient

  • A Commercial Pilot operating a Boeing 737 to Transport Passengers/Cargo

  • A Baker operating a Stand Mixer & Oven to Bake Cookies

  • An Artist operating a Chainsaw to Carve Ice Sculptures

  • A Teacher operating a Computer to Lecture Students

• An Intelligent Machine Operator performs the same primary functions as a Machine Operator, only one that knows everything about the system(s) they are operating, rather than just having a superficial understanding of how they interact with the system(s)

  • Whether CPTC/SMSCP certified or not, the primary reason to be an Intelligent Machine Operator is to INVEST IN YOURSELF

    • By starting with the foundational skills of being an Intelligent Machine Operator, you are creating the foundation of a true Engineer - one that operates not just under theory & ideas but application & implementation

    • To become a truly valuable/effective Engineer, you cannot skip these essential skills or those of a Technician (more on that on the next page!), as true Engineers do more than just "Engineer" things, but also act as Operator & Technician, whenever needed

  • By being an Intelligent Machine Operator, you:

    • Increase your technical, personal, & interpersonal experiences, knowledge, & wisdom

    • Increase your personal Health, Safety, & Overall Quality of Life

    • Advance your mindset/career & to becoming an Engineer of the future, or Engineer 4.0...

• The second step of a career in Industry 4.0 is that of a Technician 4.0, who ensure the consistency and reliability of systems and processes

  • As a Technician 4.0, your focus will be on applying your knowledge to the optimization & reliability of systems

  • As a Technician 4.0, your work will likely be spread over multiple facilities/operations across a larger region working in different cities & states as necessary to accomplish your work

• Technician 4.0's can see the system as a whole, but can also dive in and work with particular system components. More importantly, Technician 4.0's understand how the components work together. In addition to Operator 4.0 skills and knowledge, Technician 4.0's will be both high-level and low-level mechatronic systems experts.

• Following SMSCP Level 2 (Assistant / High-Level Technician), a Technician 4.0 will be able to:

  • Understand and analyze the technical specification of mechatronic systems, subsystems, modules, and components

  • Derive and determine parameters for mechatronic systems and system elements

  • Measure, interpret, and analyze electrical, PLC/microcontroller, and mechanical values

  • Assemble and install tools and hardware systems

  • Perform scheduled and preventive maintenance

  • Install, implement, and modify software tools used in mechatronic systems

  • Use troubleshooting skills to identify, foresee, and prevent possible problems, conflicts, and failures, and to systematically and intelligently make repairs

  • Program mechatronic modules and systems, especially PLCs

  • Implement PLC networks, including configuration and data transfer using bus systems

  • Analyze system logs

  • Incorporate relevant technical literature into understanding of system operation and use this information to propose procedural and operational changes

  • Observe and incorporate safety standards

  • Apply knowledge of process control technology, including all regulator types

  • Observe, follow, and influence cost control and process efficiency procedures

  • Execute all of the above as an effective member of a team

• The third step of a career in Industry 4.0 is that of a Engineer 4.0, advancing the future of the industry

  • As an Engineer 4.0, your focus will be on working directly with customers to provide innovative technical solutions to unique and complex problems

  • As an Engineer 4.0, your work will likely be spread over multiple organizational divisions across multiple large geographic regions/cultures - working in different states, countries, and/or continents as necessary to accomplish your work

• Engineer 4.0's understand how mechatronic systems function at a high level. In addition to all the knowledge and skills of an Operator 4.0 and Technician 4.0, Engineer 4.0's can understand customer requirements and translate them into the technical requirements of complex mechatronic systems. In addition to designing and managing new systems, they will
  be able to optimize and improve existing systems using Project and Process Management methods and tools.

• Following SMSCP Level 3 (Professional / Engineer), an Engineer 4.0 will be able to:

  • Understand and oversee the complete mechatronic system life cycle (e.g. impact on and from sales, marketing, production, suppliers, and maintenance)

  • Apply Project Management methods and tools

    • Understand the fundamentals of Project Management concepts like PMI and CMMI

    • Understand the principles of Team Management

  • Define the functional requirements of a mechatronic system with “use cases,” interviews with customers and users, and systems modeling techniques

    • Communication and documentation skills

    • System understanding

  • Perform high-level design by defining appropriate mechatronic systems to perform specific tasks

    • Utilize design methods and solutions

    • Transformation of customer “wish list” into technical mechatronic system specification

    • Validation of customer requirements and technical translation

  • Utilize knowledge of machine elements, actuators, pneumatics, and electric drives to design particular mechatronic systems

    • Understand and analyze the impact of new/changed mechatronic system parts from a technical point of view

    • Select the correct automation technology based on the mechanical and electronic composition of the system, while taking the functional requirements in to account

    • Use CAD tools to create and communicate electrical and mechanical design ideas

    • Understand alternative engineering solutions – e.g. priority list, cost calculations, etc.

    • Design, program, and troubleshoot PLC networks

    • Develop specifications for automation system communication integration

  • Review past system performance and carry out comprehensive system tests, with the aim of locating ways to optimize operations for cost, quality, and efficiency

    • Evaluate components/processes by having test concepts and strategies to make sure that customer requirements are met and fit into the overall mechatronic system life cycle

    • Apply principals of Claim Management, Knowledge Management, and Process Management (e.g. performance measurements)

    • Design and implement system optimization techniques in an existing mechatronic system