Job Openings >> Production Assistant
Production Assistant
Summary
Title:Production Assistant
ID:1004
Department:Operations
Description
 

JOB TITLE:              PRODUCTION ASSISTANT ~ INJECTION AND BLOW MOLD          

 

DEPARTMENT:      Molding

REPORTS TO:         Shift Manager

SUPERVISES:          None

FLSA STATUS:        Non-Exempt Hourly

 

JOB SUMMARY

Responsible for the effective and efficient operation of all scheduled and running molding machines, both injection and blow.  With the utmost attention paid to the quality of the parts being produced.

 

DUTIES AND RESPONSIBILITIES

 

  1. Start of ShiftResponsible for verification of the condition of the molding department.

 

Representative duties include:

  • Validates and documents that the box counters match the Mold Detail Analysis Report to include the current number of cavities running.
  • Inspects the setup of all presses that are running, ensuring that the right equipment is being used, the equipment is clean, and the product being produced is visually free of defects.
  • Verifies that the tracker system is updated.
  • Collects information on how the shop is running by filling out the Start of Shift Checks and Balance Report.  Note:  The information on this report helps to ensure that all equipment is functioning properly, and that all problems are addressed in a timely fashion. 

 

To be measured by:

  • Completion of all paper work.
  • Effectiveness of problem resolution.
  • Timeliness in how these tasks are completed.

 

  1. Productivity / EfficiencyAnalyzes work load and requirements, sets personal priorities bases on these work requirements, Performs all tasks in a productive and efficient manner. 

 

Representative duties include: 

  • Performs color changes, machine start-ups and shutdowns. Validates the production run by filling out the proper documentation.      
  • Updates the Shift Manager’s log by logging any problems or important information.
  • Operates, maintains, repairs and cleans all equipment, completes necessary reports such as machine trouble reports (MTR).
  • Analyzes and adjusts presses / product as required, works with QA to ensure the products meet specifications.
  • Monitors the collection and separation of all substandard products, and enters the information in the turnaround listing.

 

To be measured by:

  • Problems associated with poor color changes.
  • Accuracy of the production run.
  • Proper completion of all paper work.
  • Attention to detail as it relates to the operation of the equipment.
  • Timeliness in how these tasks are completed.
  • Effectiveness of process adjustments.
  • Reject count accuracy.

 

  1. Quality / ProductionMonitors and ensures the production of quality parts.

 

Representative duties include:

  • Cooperates with the Quality Department, and adheres to all quality procedures.
  • Ensures the production of quality parts by communicating with QCS and performing random quality checks.
  • Investigates production problems, with a goal to minimize down time and maximize the production of good quality parts.
  • Ensuring that the product being produce is the best possible, given the condition of the mold / machine.
  • Ensures that all equipment is running as efficiently as possible.  Analyzes and adjusts equipment as needed verifying that production meets quality specifications.
  • Takes part in recalling substandard product from Harmar.  Making sure all parts are sorted and the good product is returned to inventory in a timely fashion.
  • Cooperates in the investigation of customer complaints so that root causes can be determined and eliminated.
  • Maintains quality products by making adjustments for size, color, weight or other defects.
  • Repairs any oil problems that may affect quality.
  • Completes NCRs, Quality Alerts and MTRs if repairs are needed.

 

To be measured by:

  • Effectiveness of problem resolution.
  • Proper completion of paper work.
  • The number and cost of customer complaints (final customer) attributed to the Molding Department.
  • Harmar rejects attributed to Molding, measured in PPM. 
  • The number and severity of CAPA’s submitted for process-related quality concerns.
  • How well the department / Teams meet the scrap reduction goals.

 

  1. Maintenance / Preventative Maintenance:

 

Representative duties include:

  • Must be able to fluently operate presses, robots and auxiliary equipment to diagnose malfunctions, and to verify repairs.
  • Troubleshoots and locates the source of the problem by observing the operation of the equipment.
  • Brainstorms with other TeamMates as needed to solve problems.
  • Repairs minor hydraulic, pneumatic, water and electrical problems. 
  • Verifies repairs have been satisfactorily completed before returning the equipment to a production status.
  • Controls down time by scheduling repairs with the Shift Manager.
  • Maintains good communications with the Shift Manager.
  • Completes MTR’s by describing the problem, solution, parts consumed, and repair time.
  • Ensures the work is completed in an efficient and cost-effective fashion.

 

To be measured by:

  • Effectiveness of problem-resolution activities as pertains to equipment.
  • Evidence of maintenance records (MTR’s).

 

  1. Safety / HousekeepingEnsures that all operations are performed with the utmost regard for the safety and health of all personnel.

 

Representative duties include:

  • Complies with all policies, and safety regulations, establishes good housekeeping practices.
  • Responsible for maintaining a safe and healthy work environment.
  • Assists in the investigation of safety incidents, near misses, and unsafe acts.
  • Maintains a high level of communication with shift personnel.  Advises and cautions TeamMates about potential problems and dangers.
  • Takes corrective actions to ensure that all equipment utilized in the Plant is free of recognized hazards.
  • Operates all equipment in accordance with the manufacture’s recommendations.  Helps with the training of new TeamMates, passes on information related to the safe and proper use of the equipment.
  • Internal inspections result in few, if any, corrective actions. Corrective actions must be addressed in a timely fashion and not repeat in subsequent monthly inspections.
  • Makes housekeeping a day-to-day practice by ensuring that the guidelines for “Manufacturers of Food Packaging” are followed as a matter of routine.

 

To be measured by:

  • Number of unsafe acts and unsafe conditions as the cause of reported incidents.
  • Evidence of disciplinary action related to unsafe acts.
  • Number of findings reported on monthly ASI / safety inspections related to Shift operations.  To include Critical, non-critical, and reoccurring issues.

 

  1. Material HandlingPerforms a variety of duties related to maintaining material, regrind and color levels through-out the molding department.  This includes the transfer of materials such as resin, molded parts, and empty boxes. 

 

Representative duties include:

  • Transfer Coordinator if TeamMate is certified to operate Whirley forklifts/ walkrides:  Responsible for the movement of materials though out the mold department.
    • Performs daily safety/maintenance inspections on all material handling walk-rides and forklifts.
    • Performs daily inspection of the warehouse and mezzanine.
    • Completes cardboard inventory checklist at the beginning of the shift and faxes the list to Harmar Street.
    • Responsible for shipping and receiving.
    • Responsible for ticketing and wrapping all skids prior to moving them to the warehouse at color changes and shutdowns.

 

  • Material Handling: Rotation with other Production Assistants:  Ensures that the correct material, color and additives are being used for each product being produced, and that the presses do not run out of material or color.
    • Must be organized and able to efficiently and effectively maintain the material and color levels throughout the department.
    • Start of shift inspection and verification of all color and material being used.
    • Checks and empties all grinders and Dust dogs using the material when possible, storing the material in barrels or Gaylord’s as needed. Ensuring that the barrels and Gaylord’s are labeled properly.
    • Cleans filters by utilizing the air hoses in the cleaning station.
    • Maintains the lot number accuracy for all of the colors on the floor and any virgin materials in gaylords as well.

 

To be measured by:

  • Completion of all daily inspections.
  • All incoming supplies and equipment are inspected prior to being signed for.
  • Maintains a well-organized work area.
  • Raw materials are tagged and stored correctly.
  • Individual errors noted on the Mismarked Skid Report.
  • Mixes all material according to the Mold Detail Analysis Report.
  • Maintains raw material levels in such a way that the presses do not run out of material (resin / color).

 

  1. PackingSafely and efficiently moves product from the molding machine to the box.

 

Representative duties include:

  • Performs Packer duties during break times, or as required.
  • Moving product into boxes, ensuring that all parts are packed correctly according to the Mold Detail Analysis Report.
  • When applicable follows routing instructions.

 

To be measured by:

  • Accuracy - How the product is packed.

 

  1. Other:

 

Representative duties include:

  • Maintains effective communications between previous and incoming shifts by relaying all pertinent information.
  • As requested will establishes the daily work schedule for the team.
  • Participates in plant shutdowns and plant startups by starting all air compressors, water towers, water chillers and presses.
  • Performs Team Leader job as required. This includes the collection of production information from all presses that are running.  This information will be used to update the AS-400, and calculate the color changes for the next 24 hours as well as maintaining the mold status by entering the mold turnaround information (machine’s production, downtime, rejects and color change information) into the AS400.
  • Performs Transfer Coordinator/Material Handler/Color Mixer, and Packer duties as required.
  • Performs material and color testing.
  • Monitors the proper use and storage of all regrind including all regrind paperwork.
  • Reviews new mold schedule every Monday and Thursday for color changes and mold sets.
  • Monitors Packers to ensure proper packing procedures are being performed.

 

GENERAL CONDUCT

  • Maintains respectful working relationship with TeamMates, Managers, Shift Supervisors, Foreman to promote teamwork and a positive work environment.
  • Committed to Continual Improvement to raise personal performance above the standard and to develop new methods to eliminate waste, improve productivity and reduce customer complaints.
  • Maintains excellent attendance as defined in the Company’s Attendance Policy.
  • Supports, enforces and complies with all company policies and procedures, including safety and quality.
  • Submits new ideas to improve Safety, Quality and procedural operations that will benefit the Company.
  • Actively participates in meetings and discussions by providing suggestions for improvement, problem solving and offering feedback.
  • Performs duties in a manner that encourages teamwork and sets a positive example.

 

TRAINING REQUIREMENTS

  • Company Policies and Procedures
  • Safety Orientation
  • Fire Extinguisher
  • Sexual Harassment
  • Interaction Management
  • Forklift and Walk-Ride if eligible
  • Mixing Color and Material
  • Plastrac Conair Color Changes          
  • Plastrac Color Check
  • Cleaning the Grinder
  • Packing Product
  • Restarting Press after a Color Change
  • Color Change Hopper
  • Non-Conformance Reports
  • Reject Count
  • Quality Checks
  • CAML Loader Color Change
  • Purging through a Mold
  • Interthor/Gaylord Stacker
  • Adding Hydraulic Oil to Presses
  • Calibration of a Gravimetric Blender Weight Bin
  • Segregating Non-Conforming Products
  • Tower and Chiller Start-Up and Shut-Down
  • Air Compressor Start-Up and Shut-Down
  • Portable Surge Bin Pump
  • Cleaning Roto Grand Grinder
  • Starting a Blender
  • Shutting down a Blender
  • Blow Molding Start-Up
  • Blow Molding Shut-Down
  • Parison Removal
  • Purging a Single Station
  • Cleaning a Blender
  • Purging a Double Station
  • Power Failure
  • Head Calibration and Adjustments
  • Removal of Stuck Material in Blender          

                                               

QUALIFICATIONS

  • One to three years molding experience preferred.
  • Demonstrated mechanical aptitude.
  • Good color discrimination and manual dexterity.
  • Must be self-motivated and have the ability to handle multiple tasks with little supervision.
  • Certification to operate Whirley forklifts/ walkrides preferred.

 

PHYSICAL DEMANDS

  • Prolonged standing and walking on hard surfaces.
  • Climbing of stairs and ladders. Bending, crouching, and squatting.
  • Pushing, pulling, lifting and lowering workloads of up to 45lbs.
  • Reaching above shoulder height.  Must wear steel-toed shoes.
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