JOB TITLE: Process Technician – Injection Molding 

DEPARTMENT: Molding 

REPORTS TO: Molding Technical Manager 

SUPERVISES: None 

FLSA STATUS: Non-Exempt/Hourly  

JOB SUMMARY: 

Pulls and sets molds, solves problems associated with problematic equipment, molds, and process.  Responsible for R&D work associated with new molds and new materials.  Trains molding department personnel as needed.   

DUTIES AND RESPONSIBILITIES: 

Mold Sets: Sets molds as requested, ensuring that the press / mold are running as efficiently as possible. 

• Removes and sets molds into machines by utilizing forklift, disconnecting, and connecting electric, air, water, and ejector stakes.  

• Follows set guidelines for part qualification. 

• Operates and monitors machines and robots until they are on cycle and running well.  Completes the necessary set-up paperwork. 

• Performs color changes when necessary. 

• Monitors presses for proper operation and settings ensuring proper pressures and temperatures.   

• Monitors and adjusts machine cycle as needed. 

Quality: Responsible for the quality of the mold set, process, and product being produced.   

• Cooperates with the Quality Department, following set guidelines for part qualification. 

• Monitors machine, mold, and auxiliary equipment for proper operation.  Ensures that all equipment is running as efficiently as possible, and that production meets established standards. 

• Investigate production problems, with a goal to minimize down time and maximize the production of good quality parts. 

• Ensure that product being produce is the best possible, given the condition of the machine, and mold. 

• Works with the Quality Department to establish acceptable conditions as needed. 

• Cooperates in the investigation of customer complaints so that root causes can be determined and eliminated. 

• Participates in and provides feedback on quality improvement and corrective action projects. 

• Helps train and retrain Production Team, with a goal to improve the quality of our product, by improving the skills of the TeamMates. 

Productivity / Efficiency: Monitors and maintains mold cycle times, cavitation, and quality, with a goal to run the equipment / molds as efficiently as possible. 

• Works with Engineering, Quality and Machine Shop to address product non-conformances to identify and implement corrective actions.  

• Follows established manufacturing standards, requests review when necessary. 

• Reports test results following the shooting of a new, revised, or repaired mold. 

• Set goals that will help to improve productivity and efficiencies. 

• Supports and implements continuous improvement projects that improve productivity and efficiency. 

• Responsible for the care and safekeeping of our equipment such as: molding machines, molds, robots, auxiliary equipment, and tools. 

Maintenance: Assists with the general repair of equipment in the Molding Department.  

• 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 maintenance personnel, and outside technical support as needed. 

• Restores damaged or malfunctioning equipment to operation by repairing, replacing and or adjusting electrical, mechanical, hydraulic, and pneumatic systems. 

• Verifies repairs have been satisfactorily completed before authorizing return of equipment to production status. 

• Controls down time by scheduling repairs with the Molding Technical Manager. 

• Maintains good communications with Molding Technical Manager, and Shift Manager. 

• Completes MRO’s by describing the problem, solution, parts consumed, and repair time. 

• Assists other maintenance personnel as needed. 

• Conserves maintenance resources by using equipment and supplies as needed to accomplish job results. 

• Ensure the work is completed with technical excellence, and in an efficient and cost-effective fashion. 

• Assists Mold Maintenance TeamMates with mold problems and transportation of molds between buildings. 

• Performs Bi-annual press PM’s and inspections as requested.  

R&D Molds / Material:  Performs Capability Studies and other tests on new molds, problematic molds, and raw materials (Resin / Color / Purge Compound / etc…) with plastic engineering.  

• Performs Capability Studies, providing information, and recommendations to the Engineering Department.  Information that helps to ensure new molds and revised molds operate smoothly and within SPC parameters. 

• Must work with the Quality Department to ensure all tests and required parts are made in accordance with the test packets. 

• Perform tests on sample materials and colorant, provide documentation and recommendations on the test results. 

Safety Housekeeping: Responsible for maintaining a clean, safe, and healthy work environment.  Ensuring that mold sets and maintenance operations are performed with the utmost regard for the safety and health of all department personnel. 

• Maintains a safe and clean work environment. 

• Makes housekeeping a day-to-day practice, follows the SQF guidelines. 

• Follows all policies, safety regulations, establishing good housekeeping practices. 

• Operates all equipment in accordance with manufacture’s recommendations. 

• Ensures that all equipment utilized in the plant is free of recognized hazards. 

• Ensures safety devices are all in place and operational. 

• Implements changes that will reduce safety hazards. 

• Assures tools and other equipment are stored properly. 

• Maintains a high level of communication with Molding Technical Manager and other appropriate personnel. 

• Advises and cautions TeamMates about potential problems and dangers. 

Other: 

• Supports the team on duty when there is a maintenance requirement. 

• Assists in the training of new TeamMates in machine operations. 

• Must be able to work overtime in emergencies or special situations at the request of the Molding Technical Manager. 

• Performs all duties in an independent manner with little or no supervision. 

• Wears proper PPE. 

• Maintains professional and technical knowledge by attending educational workshops. 

GENERAL CONDUCT: 

• Maintains respectful working relationship with TeamMates, Managers, Shift Supervisors, Foreman to promote teamwork and a positive work environment. 

• Committed to Continuous Improvement 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. 

TRAINING: 

• Company policies and procedures 

• Sexual Harassment 

• Safety Orientation 

• Fire Extinguisher 

• Lock-out/Tag-out – Authorized.  

• Forklift and Genie Boom 

• Fall Protection 

• Injection Mold Startup and Shutdown 

• Color Change Hopper 

• Set Plastrac up. 

• APD 

• IQMS 

• Calibration of Gravimetric Blender 

• Material Dryer 

• Extrusion Machine 

• Startup and shut down of preform process. 

REQUIRED SKILLS / ABILITIES:  

• Willingness to work in a collaborative workplace and like to contribute ideas to improve operations.  

• Be able to work under time pressure and prioritize and complete tasks in a timely manner.  

• Be able to maintain a positive and cooperative attitude daily and under deadlines.  

• Must possess above average language and math skills, and reasoning abilities.  

• Have a strong desire to learn technical manufacturing skills.  

• Enjoy new, hands-on challenges. 

EDUCATION AND EXPERIENCE: 

• High school diploma or equivalent required.  

• 3 to 5 yrs. experience as a Mold Setter required.  

• Good manual dexterity 

• Good color discrimination.  

• Good working knowledge of hydraulics, pneumatics, electrical, blueprints.  

• Must be certified to operate Whirley forklifts. 

• Ability to complete tasks with minimal supervision. 

PHYSICAL REQUIREMENTS:  

• Prolonged standing or walking on hard surfaces.   

• Climbing stairs and ladders.  

• Bending, crouching, squatting to lift or lower workloads.  

• Lifting of 45 lbs.  

• Must wear steel-toed shoes.