JOB SUMMARY

Packer 1 - is responsible for the production and/or packaging of a variety of manufactured products. The Packer position is a support role for several areas of manufacturing, including but not limited to; injection molding, Stretch Blow Molding, Extrusion Blow Molding and Quality.

Material Handler - Performs a variety of duties throughout the Molding Department including making move transactions in the computer system using handheld scanners or a tablet for needed items. Safely transport items around the Molding Department with powered lifts and walk ride equipment. Also responsible for maintaining the raw material levels at each machine (resin and color). The TeamMate will perform this portion of the job as needed due to absences or production requirements.

CORE RESPONSIBILITIES

1. Packing:  Safely and efficiently moves product from the molding machine to the box and then to the designated pick-up area.

• Perform production duties such as manual lifting, packaging, taping, labeling operations, and sorting.
• Moving product into boxes, ensuring that all parts are packed correctly according to the Work Order and packing directions on the set-up sheet.  There are three main methods of packing:
  • Hand stack – Moving and stacking product from a catch bin into a box.
  • Drops – These are free fall parts; the box is changed when the conveyor stops, and the box counter alarms.
  • Robot – Placing a box over parts that have been organized and stacked by a robot.
• Move product and inventory using a Pallet Jack.
• Maintains a clean, safe, and healthy work environment by sweeping floor, picking up debris and parts and follows set 5S standards on all work centers. Press cleanings are documented in IQMS once per shift.
• Report defective materials or questionable conditions on all products to the Shift Manager, Team Leader, Production Assistant or QCS.
•  Periodically verifies component part quantities (parts per bag). Notifies shift Manager/ Team Leader if issues are found.
• Notifies proper TeamMates of machine problems by paging over the intercom system, radio, or other means.
• Execute and document quality inspections twice per shift in IQMS.
• Follow all recommended Safety Practices and procedures.
• Perform related duties as required by supervision.
• Break down cardboard for recycling.
• Retrieves pallets, boxes, lids, and other supplies.
• Grind’s runners and rejects as required by the molding process. 
• Records rejects as needed in IQMS and cleans off parts that fell on the floor.

2. Material Handling:  Performs a variety of duties throughout the Molding Department including making move transactions in the computer system using handheld scanners or a tablet for needed items. Safely transport items around the Molding Department with powered lifts and walk ride equipment. Also responsible for maintaining the raw material levels at each machine (resin and color).

DUTIES / RESPONSIBILITIES:

1. Safety, Housekeeping and SQF
   • Inspects material handling equipment for defects, fills out proper maintenance requests and returns to Molding Administrative Assistant to contact Vehicle Maintenance for repairs.
   • Operates powered industrial trucks, sit down, and walk ride to move materials to and from locations.  Completes a forklift checklist prior to operation.  Refers all problems to vehicle maintenance for repair.  Adheres to traffic safety program.
   • Safeguards material handling operations and warehouse contents by establishing and monitoring security procedures and protocols. 
   • Ensures that all operations are performed with the utmost regard for the safety and health of all personnel involved.

• • Makes housekeeping a day-to-day practice by ensuring that the SQF guidelines are followed as a matter of routine. Internal inspections should result in few, if any, corrective actions. Corrective actions must be addressed in a timely fashion and not repeated in subsequent Whirley inspections.
  • Restack leaning boxes and replace damaged boxes or pallets.
  • Keeps warehouse areas free from stray parts.
  • Reports any safety concerns or damage to the building/ warehouse area to Shift Manager or Team Leader.

2. Material Handling
   • Responsible for the scanning and movement of plastic materials/ coloring though out the Molding Department.
   • Checks Molding Department Work Centers for status of orders being produced.
   • Operates a computer to gather information or create picklists for components needed for production.
   • Returns all extra components to appropriate warehouse and properly stores parts.
   • Removes Work in Progress (WIP) and Finished Goods (F/G) from Molding Department and stages appropriately on dock.
   • Stores and replenish stock locations to meet inventory needs.
   • Checks and replenishes all components and other supplies in the warehouse.
   • Maintains the battery levels on all batteries. Responsible for equalization of the batteries once per week.
   • Completes cardboard inventory checklist at the beginning of the shift and gives to Shift Manager/ Team Leader. 
   • May be required to drive Company box trucks to transport materials between buildings.
3. Raw Materials Management
   • 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.
   • 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.
   • Follows first in / first out requirements when pulling raw material/ color from inventory.
   • Must weigh all color and raw material prior to returning it to inventory, documentation on the containers must be updated and accurate, lids sealed with stretch wrap.  Color / material quantity and storage location must be updated. 
   • Must weigh and tag all re-pelletized material and turn in required paperwork to the Molding Administrative Assistant.
   • Cleans/ changes filters from vacuum pumps, surge bin, compressed air machine loaders, by utilizing the air hoses in the cleaning station.

4. Packing During Breaks 

• Moving product into boxes, ensuring that all parts are packed correctly.
• Safely and efficiently moves product from the molding machine to the appropriate box.      
• Ticketing and scanning the finished boxes and placing them on skids in the correct configuration.
• Shipper boxes must be stretch wrapped before being moved from the machine. 
• Transport full skids to the transfer area by using a pallet jack. 
• Retrieves pallets, boxes, lids, and other supplies.
• When applicable follows routing instructions.
• Grind’s runners and rejects as required by the molding process. 
• Documents all rejects that have been reground in the Blow Molding area.

5. Other Responsibilities as Assigned
   • Communicates with other shifts and departments to pass and gather information concerning daily duties.
   • Assists Receiving by unloading shipments manually. Completes all necessary paperwork associated with shipment.
   • May be required to work overtime to meet the department’s operational needs.
   • Sorts regrind when staging to go to Sparkle Warehouse.

GENERAL CONDUCT:

• Maintains respectful working relationship with all Whirley TeamMates and supervisors to promote teamwork and a positive work environment.
• Committed to Continuous 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 Good Ideas/ Kaizens 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.

REQUIRED TRAINING:

• Company Policies and Procedures
• Safety Orientation
• Fire Extinguisher
• Powered Industrial Truck
• IQMS
• RF System

• Bills of Lading
• Packing Product
• Quality Checks
• Segregating Non-Conforming Product

REQUIRED SKILLS / ABILITIES:

• Understand and follow basic verbal and written instructions.
• Effectively communicate information and respond to questions from various levels within the organization.
• Possess basic mathematical skills: addition, subtraction, multiplication, and division.
• Perform basic visual quality inspections on products.

EDUCATION AND EXPERIENCE:

• High School Diploma or equivalent  

PHYSICAL REQUIREMENTS:

• May be required to stand and walk for long periods of time.
• May involve some repetitive motions.
• Must be able to lift up to 45 pounds.
• May also engage in frequent bending, stooping, squatting, pushing and pulling of parts and part containers

SPECIAL REQUIREMENTS:

Driving records for TeamMates holding Material Handler positions will be subject to periodic review from a third party.  Failure to maintain an acceptable driving record could result in job loss or reassignment.

Drivers with unacceptable driving records would include those with one or more of the following violations:

• Violation(s) of company Drug and Alcohol Policies
• Conviction for an alcohol and/or drug related driving offense
• Refusal to submit to a Blood Alcohol Content (BAC) test.
• Conviction for reckless driving
• Any combination of three or more moving violations, "At Fault Accidents", or "Preventable Accidents" within the most recent three years
• Suspension, revocation, or administrative restriction within the last three years
• Leaving the scene of an accident as defined by state laws.
• At fault in a fatal accident
• Felony committed involving a vehicle.
• Three or more "Company Vehicle" physical damage claims in any twelve-month period