Description

The Production Mechanic is to maintain and assist in 1st quality production and efficiency through the process of ensuring necessary repairs of malfunctioning knitting machinery.

Definitions: QA Quality Alert

Attachments:

• 8.3.111 BARCO Flow Chart (mechanic)
• 6.2.2.2510 Broken Needle Replacement

Expectations:

• Understand and comply with all company policies, standards, rules and regulations as documented in Employee Handbook and subsequent postings, notifications and training sessions.
• Maintain high level of housekeeping essential to the efficient production of high quality knit fabrics.
• Positive example to other employees.

Safety:

• Never wipe off the bedplate of a knitting machine with a rag while the machine is running as this is a Safety Hazard and may also damage the machine.
• Safety glasses, offering full eye protection must be worn when using compressed air for cleaning.
• Air hoses must be returned to hangers, coiled on hanger or otherwise stationed so that there is no risk of trip hazard.
• Scissors, snips and clips must have sharp points rounded off.
• Any trip, slip and/or fall hazard must be eliminated immediately, even if the hazard exists in an area other than your immediate work area.
• All associates with hair below their shoulders will have their hair pulled back in a ponytail or encased in a hair net.
• Use safe lifting techniques. Do not lift more than 75 pounds without assistance.
• Get supervisor clearance before performing any operation that may result in injury. BE SAFE!!

Beverly Employee Responsibilities:

• Ask for additional training if you find yourself in a situation that you are unfamiliar with. Do not take chances with Safety or Quality!
• Understand and comply with company standards, rules, procedures and policies. Offer suggestions for improvement of procedures that improve quality levels, increase efficiency and improve communications.
• Take independent action to assure the safety of employees, improve quality and efficiency.
• Be a positive contributor seeking improvements.
• Continuously learn and train others in your knowledge.
• Be accountable for your actions and results.
• Seek continuous improvements allowing Beverly Knits to continue to be a market leader so that future jobs are assured.

Job Specific Responsibilities:

• Make sure to have necessary tools in order to perform job and duties
  • IPOD for BARCO messaging
  • Safety Glasses
  • Latch brush
  • Hex/Allen Wrenches
  • Knitting Scissors
  • Yarn pick
  • Needle Pliers
  • Marker
  • Press off Kit
  • Clamps & Heat Gun
  • Flashlight
• Identify and repair the following defects:
  • Load up
  • Press Off
  • Broken Needle
  • Bad Yarn Feeder
  • Spun End Out (SEO)
  • BARRE
• Check and respond to BARCO IPOD device and BARCO procedures for defective machine status to assure all repairs are met in an accurate and timely fashion(See BARCO flowchart attachment for list of defects 8.3.111)
• Understand BARCO device procedure for repairing machine;
  • BARCO Device To Repair Machine Procedure:
  • LOG ON to BARCO with your respective ID number
  • Identify cause of defect.
  • Make necessary repairs to machine.
  • If a mechanic has identified a defect inconsistent with the BARCO notification sent to his/her device, it’s the mechanics responsibility to update their findings using the proper declaration code associated with the defect in BARCO.
  • Once repaired, run machine and check fabric for defects.
  • While running quality check, check the machine for properly creeled yarn, threading, tension devices, stop motions and wraps on feeders. If changing knitting elements or yarns, take cut to stretch table to verify correction is complete. Request a pot dye check if there is a yarn concern. Make sure to LOG OFF of BARCO before moving on to the next defective machine
  • On the occasion that the machine still has defects in the fabric once running, repeat steps 2-5.
  • If you have performed step 7 a total of 3 times with no improvement in the fabric, LOG OFF of BARCO, then notify supervisor using declaration code in BARCO.
  • After calling for supervisor, and before proceeding to next defective machine, you must find supervisor to report your findings so that they may take further action to repair machine.
• Comply and understand procedures for Quality Alerts and the process for issuing QA tickets. (see attachment for Quality Alert Ticket Procedure)
  • The production Mechanic may be notified when a machine has been issued a quality alert ticket (depending on mechanics level of experience), either by his/her supervisor or through their BARCO device.
  • It is very important that the mechanic fills out quality Alert Ticket properly after repairs have been made and sign.
  • If a production Mechanic is unable to repair the defect referenced on the QA ticket, it is the responsibility of the mechanic to report to the supervisor with your findings.
  • The supervisor will then assign the machine to an experienced or Setup Mechanic.
• Mechanic is prohibited from inserting any foreign object in the go or stop button or disabling in any way the stop motions on any knitting machines.

Qualifications

Minimum Qualifications:

• Physical abilities to stand, walk and kneel on concrete floors, climb ladders, lift 20 pound cones, move 75 pound rolls and reach above head to stock creels, bend/stoop, pull materials and sufficient dexterity to thread machines and tie knots.
• Must be able to tolerate exposure to lint, chemicals and heat in summer months.
• Minimum education requirements include being able to read and write in English to fill out tickets, read and understand instructions and explain problems. The job requires frequent communications with mechanics, inspectors and support personnel.
• Must comply with all safety, quality and production requirements and instructions.
• Ability to learn and analyze.
• Desire to contribute to the company’s continuous improvement process.
• Successfully complete Production Mechanic Training and Production Mechanic Qualification test.
• Successfully complete and understand basic knitting training and responsibilities.