Position Summary: Responsible for the swift and efficient troubleshooting of production processing runs and then minimization of production waste, specifically scrap and rework. Success will be measured by scrap as a percentage of sales, downtime due to processing issues, and logged cycle time improvements against the KPP standard. Essential Job Functions include, but not limited to, the following:
· Ability to troubleshoot injection molding processes using scientific and data-driven methods.· Good problem-solving skills.· Maintain safe working environment by ensuring the company's procedures and policies are followed.· Be willing and able to do everything outlined in the essential job functions for the molder position whenever required by their supervisor.· Be able to teach and train operators and molders as needed.
· Utilize Plex to accurately account for and track proper status and proper disposition of materials.· Track and improve cycle time improvements.
· Effectively be able to evaluate and troubleshoot processes to reduce scrap and cycle times.
· Respond to machine alarms and efficiently resolve/root cause those issues to keep the presses running.
· Work on assorted improvement projects including but not limited to: scrap reduction, process improvements, cycle time reductions, operator efficiency improvements, cost reductions, safety improvements or QIOR resolution.
· Audit processes to the KPP to ensure accuracy.
· Ensure part weights and cycle times are accurate to the KPP.
· Own and resolve process-related work orders.
· Ability to safely operate a hi-lo and a crane.
· Additional functions not specifically outlined in this position description as assigned by the supervisor.
· Ensure compliance with Pliant's environmental management system and look for opportunities to reduce our impact on the environment.
· Associate/Bachelor of Science Degree in Plastics Technology/Plastics Engineering Technology (or related courses in Plastics Technology, Injection Mold Design, and Manufacturing Processes) & 4 years experience.
· 5 years injection molding experience in a similar injection molding environment.
· Understanding of injection mold qualification and initial injection molding process development and validation,
· Demonstrated abilities in plastic processing control, improvement, debugging, & cycle time reduction.
· Understanding of and ability to effectively apply general molding concepts of non-Newtonian flow; pressure limited injection, and systematic de-coupled molding.
· Thorough understanding of IMM machine states, various types of IMM controllers, and process monitoring capabilities.
· Technical writing ability and good verbal communication skills.
· Computer skills and familiarity with Microsoft Word and Excel.
· Experience in group leadership and structured team approach to problem solving.
· Experience with and a sound understanding of the flow characteristics, molding parameters, & properties of various engineering/conventional grade resins common to the injection molding industry.
· Demonstrated analytical & mechanical abilities.
· Demonstrated ability to perform basic math calculations pertinent to injection molding process & tool design (mold types, heat transfer, runner & gate design, venting, mold components, & materials).
· Perform part sampling on production molds as needed for material samples or problem solving activities, in accordance with specified instructions. Record process parameters, lessons learned, and any part, mold, or process problems encountered in this sampling process.
· Develop key molding process parameters for existing and new products & tooling utilizing a systematic method to determine the optimum material conditions (temperature, flow rate, pressures, cooling rate/time, etc.) using proven and universally accepted injection molding principles.
· Establish initial injection molding machine (IMM) settings necessary to achieve key processing parameters.
· Establish appropriate process monitor set points and tolerances necessary for control/detection of machine conditions leading to part defects and/or equipment damage.
· Document and preserve key processing parameters, IMM settings, and electronic data associated with established molding processes and process monitoring.
· Train molders and Process Technician I's to understand, measure, & use the key processing parameters and injection molding principles (“rules of thumb”) to transfer, troubleshoot, and make minor adjustments to the injection molding process in a controlled, systematic and logical manner.
· Verify adequacy of injection molding machine clamp, injection pressure & process monitoring capabilities of various IMMs in relationship to part/tool design and quality constraints.
· Perform tool qualification for repaired or reworked injection molds. Recommend, initiate & coordinate mold design improvements and repairs with Pliant Tooling.
· Assess existing injection molding processes & identify production process improvement opportunities – appropriately control, implement & document process changes necessary to enhance effectiveness and efficiency.
· Use statistical data collection to monitor machine and process performance.
· Provide technical support to Manufacturing by assisting molders with root cause analysis and corrective actions.
· Support new mold sampling demands as needed to meet urgent customer requirements or fill in for absence personnel.
Focus on cycle time improvements, scrap reduction, and “best” manufacturing practices, including QMC and Lean methods.
· Mentor the mold set-up team and Process Technician 1's by encouraging them to continue gaining knowledge and learning new skills to make their jobs easier and flow better (work smarter, not harder). Pass on knowledge to help prepare them for future promotion(s) within Pliant.Ensure compliance with Pliant's environmental management system and look for opportunities to reduce our impact on the environment.
· Establish appropriate process monitor set points and tolerances necessary for control/detection of machine conditions leading to part defects and/or equipment damage.
· Train molders and Process Technician I's to understand, measure, & use the key processing parameters and injection molding principles (“rules of thumb”) to transfer, troubleshoot, and make minor adjustments to the injection molding process in a controlled, systematic and logical manner.
· Verify adequacy of injection molding machine clamp, injection pressure & process monitoring capabilities of various IMMs in relationship to part/tool design and quality constraints.· Perform tool qualification for repaired or reworked injection molds. Recommend, initiate & coordinate mold design improvements and repairs with Pliant Tooling.
· Performs timeclock record reconciliation, evaluations, and discipline including written warnings and terminations.· Use statistical data collection to monitor machine and process performance.· Provide technical support to Manufacturing by assisting molders with root cause analysis and corrective actions.but not limited to; safety glasses/goggles & steel toe work shoes and hard hat when required.
