Process Technician

Summary

Responsible for the setup, startup, diagnosis, and troubleshooting of the injection molding presses, all auxiliary equipment, and all secondary production equipment while ensuring that safety and quality are the prime initiatives. Ensure all machines run at optimum cycles. Document process settings, process changes, water diagrams or anything that may be pertinent to aid in future setups and production runs. This position acts as the direct supervisor of all machine attendants, operators, material handlers, and grinders on the shift.

Shift Leader Requirements

• Provide leadership and direction for other team members, assign tasks and machines to operators
• Direct and maintain machine operators and senior machine operators during the shift

• Assist with training new hires as needed
• Get contact phone numbers from new employees.
• Work with Production Leader if employees are absent to find coverage
• Update HR on absent employees for the shift.
• Ensure all time cards and attendance sheets are filled out correctly on a daily basis
• Ensure all employees are wearing safety glasses and PPE- needs to be enforced, with (1) verbal warnings and then written warnings from there as needed.
• Work with the Production Leader to ensure all machine operators clean and organize their areas prior to shifting change.
• Work with the Production Leader on employee performance and disciplinary issues.

Process Technician Requirements

• Responsible for the setup, startup, diagnosis, and troubleshooting of the injection molding presses, all auxiliary equipment, and all secondary production equipment while ensuring that safety and quality are the prime initiatives.
• Ensure all machines run at optimum cycles.
• Document process settings, process changes, water diagrams or anything that may be pertinent to aid in future set ups and production runs.
• Follow all department and company-wide safety policies and procedures
• Communicate effectively and professionally with superiors and co-workers in a team environment
• Trouble-shoot all process problems and make corrections; discriminate between process-related problems, mold-related problems, and machine-related problems
• Ensure all quality attribute inspections are completed on a timely basis (visual/dimensional) and correct any non-conformances or machine malfunctions immediately. Inform the quality of non-conformance
• Accurately count/weigh parts for correct packaging
• Package all parts and build pallet quantities according to job specifications
• Perform minor machine and mold maintenance (e.g. cleaning, removing blockages, lubrication, repairing minor water or hydraulic leaks)
• Verify mold installation is correct, establish a process starting point, and control parameters
• Complete job start-ups and document activities on the Master Job Sheet (MJS) in a timely manner
• Submit start-up part samples for quality control measurement and evaluation in a timely manner
• Maintain a clean and safe work area by performing routine audits of employee assigned areas, report any and all unsafe acts or conditions to the Production/Safety Manager immediately
• Be able to perform all regular duties of machine operators and senior machine operators as needed
• Assist material handler with machine operator/senior machine operators to break periods during the shift, fill in as needed so operators may take an uninterrupted break
• Ensure that the operators accurately record production quantities and downtime codes for the shift
• Ensure that all parts produced meet quality and packaging standards
• Maintain or exceed production and quality performance requirements
• Remove excess flashing, burrs, and gate connections from all parts in a manner consistent with quality standards
• Attend/operate all assigned molding machines, auxiliary equipment, and hand tools in an efficient and safe manner
• Perform regular machine and mold (in the machine only) maintenance
• Follow 5-S procedures
• Change molds when required
• Separate materials for recycling, cleaning, and organization
• Ensure all machine operators are trained; ensure timely adherence and completion of the new hire learning path
• Study the daily production reports
• Knowledgeable of mold design, mold preparation and installation, and machine maintenance requirements
• Attend and conduct weekly meetings/huddle
• Follow company policies as outlined in the employee handbook
• Regular and predictable attendance is an essential function of this job
• Other duties as assigned

Position Specifications and Requirements

• Ability to understand, read, write English, Bi-lingual would be a plus
• Minimum five (5) years of successful injection mold machine operator experience
• Good knowledge of plastics, PVC, materials/resins
• Ability to discriminate between acceptable and unacceptable parts; dimensional or visual characteristics
• Usage of the electronic device is a prerequisite of the job
• High school diploma or equivalent is required, a certificate of training beyond high school is preferred
• Ability to handle several tasks simultaneously
• Ability to work in a team environment and follow directions
• Proficient to excellent problem-solving skills
• Basic math skills
• Ability to work in a warm environment
• Ability to work as a member of a team
• Basic computer knowledge
• Significant knowledge of the injection molding process, equipment and machines (180 to 1000 ton presses)

Physical and Mental Demands

• Standing/sitting – Standing with the continuous movement for up to 12 hours
• Lifting/Carrying – Push, pull and/or lift up to 50 pounds frequently
• Bending/Reaching – Frequent bending and reaching
• Walking/Climbing – Frequent walking, occasional climbing
• Hand Tasks – Good manual dexterity required (both hands) for removing, packing, and measuring parts.
• Mental Capacity – Above-average math skills for measuring, estimating, and checking parts for correct dimensions, and process calculations

Regular Contacts: Production Manager, Tooling Technician, Maintenance Technician, Set-Up Technician, Quality Technician, and Production Planner