Title: | Decoupled and Injection Molding Process Technician |
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ID: | 1090 |
Department: | Operations |
JOB TITLE: PROCESS TECHNICIAN – Injection and Decoupled Molding
DEPARTMENT: Molding
REPORTS TO: Shift 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 TeamMates as needed.
DUTIES AND RESPONSIBILITIES
- Mold Sets: Sets molds as requested, ensuring that the press / mold are running as efficiently as possible.
Representative duties include:
- Attends and participates in the Molding Department morning meeting to receive assignments for the day.
- Removes and sets molds into machines by utilizing forklift, disconnecting and connecting electric, air, water, ejector stakes.
- Follows set guide lines 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.
- Responsible for all data related to daily activities, ensures this data is provided to the Molding Management Team.
- Monitors presses for proper operation and settings ensuring proper pressures and temperatures.
- Monitors and adjusts machine cycle as needed.
To be measured by:
- On time production measured by the % of orders where manufacturing is completed on time using the molding schedule complete by date as the baseline.
- Data associated with specific mold sets.
- Care and safekeeping of company equipment and tools.
- Effectiveness of problem-resolution activities as pertains to materials, tools, equipment, and processes.
- Communications with Molding Management Team on items impacting productivity and efficiency.
- Quality: Responsible for the quality of the mold set, process, and product being produced.
Representative duties include:
- 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.
- Investigates production problems, with a goal to minimize down time and maximize the production of good quality parts.
- Ensures that product being produced 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 to train and retrain Production Team, with a goal to improve the quality of our product, by improving the skills of the TeamMates.
To be measured by:
- Number of and cost of customer complaints attributed to the Molding Department.
- Number and severity of corrective actions submitted for process-related quality concerns associated with mold sets.
- Productivity / Efficiency: Monitors and maintains mold cycle times, cavitation, and quality, with a goal to run the equipment / molds as efficiently as possible.
Representative duties include:
- Works with Engineering, Quality and the 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’s goals that will help to improve productivity and efficiency’s.
- 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.
To be measured by:
- On time production measured by the % of orders where manufacturing is completed on time using the mold schedule complete by date as the baseline.
- Care and safekeeping of company equipment and tools.
- Effectiveness of problem-resolution activities as pertains to materials, tools, equipment, and processes.
- Communications with Molding Management Team on items impacting productivity and efficiency.
- Maintenance: Assists with the general repair of equipment in the Molding Department.
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 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 Management Team.
- Maintains good communications with Molding Management Team, Molding Technical Manager, and TeamMates.
- Completes MTR’s by describing the problem, solution, parts consumed, and repair time.
- Assists other maintenance TeamMates as needed.
- Conserves maintenance resources by using equipment and supplies as needed to accomplish job results.
- Ensures the work is completed with technical excellence, and in an efficient and cost-effective fashion.
- Assists Molding Maintenance TeamMates with mold problems and transportation of molds between buildings.
- Performs Bi-annual press PM’s and inspections as requested.
To be measured by:
- Effectiveness of problem-resolution activities as pertains to equipment.
- Evidence of maintenance records (MTR’s).
- Care and safekeeping of company equipment and tools.
- Communications with Molding Management Team on items that impact productivity and efficiency.
- R&D Molds / Material: Performs Capability Studies and other tests on new molds, problematic molds, and raw materials (Resin / Color / Purge Compound / etc…).
Representative duties include:
- 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.
- Performs tests on sample materials and colorant, provide documentation and recommendations on the test results.
To be measured by:
- Proper completion of Test packets.
- Effectiveness of problem-resolution activities as pertains to R&D Molds / Material.
- Effectiveness of Communications with Engineering, Quality, Molding Management Team.
- 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.
Representative duties include:
- Maintains a safe and clean work environment.
- Makes housekeeping a day-to-day practice, follows the guidelines for “Manufacturers of Food Packaging” (ASI).
- 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 high level of communication with Molding Management Team and other appropriate personnel.
- Advises and cautions TeamMates about potential problems and dangers.
To be measured by:
- Number of unsafe acts and unsafe conditions related to mold sets / maintenance.
- Number of findings reported on monthly ASI / safety inspections related to mold sets / maintenance.
- Other:
Representative duties include:
- Supports the team on duty when there is a maintenance requirement.
- Assists in the training of new TeamMates in machine operations.
- Maintains voucher system to track equipment repairs costs.
- Performs on-call duty, on a rotational basis, for after-hours and emergency situations.
- Must be able to work overtime in emergency or special situations at the request of the Molding Management Team.
- Performs all duties in an independent manner with little or no supervision.
- Oversees the unloading of plastic pellets from railcars or trucks.
- Wears proper PPE.
- Maintains professional and technical knowledge by attending educational workshops.
GENERAL CONDUCT
- Maintains respectful working relationship with TeamMates, Managers, and Supervisors.
- 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.
REQUIRED TRAINING
- Company policies and procedures
- Sexual Harassment
- Safety Orientation
- Fire Extinguisher
- Lock-out/Tag-out – Authorized
- Forklift and Genie Boom
- Fall Protection
- Tower and Chiller Startup and Shutdown
- Air Compressor Startup and Shutdown
- Portable Surge Bin Pump
- Injection Mold Startup and Shutdown
- Mixing Color and Material
- Non-Conformance Report
- Adding Hydraulic Oil to Press
- Segregating Non-Conforming Products
- Blender Startup and Shutdown
- Conair Color Changes
- Conair Color Checks
- Color Change Hopper
- Oil Filtration
- CAML Color Change
- Purge Through Mold
- Calibration of Gravimetric Blender
- Material dryer
- Extrusion machine
- Startup and shutdown of two shot process
- Startup and shut down of preform process
QUALIFICATIONS
· 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, blue prints.
· Must be certified to operate Whirley forklifts.
· Ability to complete tasks with minimal supervision.
PHYSICAL DEMANDS
- Prolonged standing or walking on hard surfaces.
- Climbing of stairs and ladders.
- Bending, crouching, squatting to lift or lower work loads.
- Lifting of 45 lbs.
- Must wear steel-toed shoes.