Job Openings >> Decoupled and Injection Molding Process Technician
Decoupled and Injection Molding Process Technician
Summary
Title:Decoupled and Injection Molding Process Technician
ID:1090
Department:Operations
Description

JOB TITLE:              PROCESS TECHNICIANInjection 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

 

  1. 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.

 

  1. 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.

 

  1. Productivity / EfficiencyMonitors 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.

 

  1. 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.

 

  1. 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.

 

  1. 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.

 

  1. 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
  • Color Change for a Gravimetric Blender Injection Press
  • 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.
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