What are the responsibilities and job description for the Master Glass Vial Machine Operator position at Gerresheimer?
Gerresheimer is an innovative systems and solutions provider and a global partner for the pharma, biotech and cosmetic industries. The company offers a comprehensive portfolio of pharmaceutical containment solutions, drug delivery systems and medical devices as well as solutions for the health industry. The product range includes digital solutions for therapy support, medication pumps, syringes, pens, auto-injectors and inhalers as well as vials, ampoules, tablet containers, infusion, dropper and syrup bottles and more. Gerresheimer ensures the safe delivery and reliable administration of drugs to the patient. With 35 production sites in 16 countries in Europe, America and Asia, Gerresheimer has a global presence and produces locally for regional markets. With around 12,000 employees, the company generated revenues of around €2bn in 2023. Gerresheimer AG is listed in the MDAX on the Frankfurt Stock Exchange (ISIN: DE000A0LD6E6).
Position Summary – Master Glass Vial Machine Operator.
We are seeking a skilled CNC Machine Operator with expertise in glass forming and a strong attention to detail. This role is responsible for setting up, operating, and maintaining a custom rotary indexing machinery to manufacture pharmaceutical-grade glass vials while ensuring strict quality standards. The ideal candidate will have knowledge and experience related to the hot working of glass tubes and then the high-speed formation of glass medical vials from those tubes. The candidate should also be able to identify small defects such as cracks, bubbles, surface imperfections, and dimensional inconsistencies that could compromise product integrity.
Key Responsibilities
- Machine Setup & CNC Operation
- Program, set up, and operate CNC-controlled glass forming equipment to shape pharmaceutical vials according to precise specifications.
- Adjust parameters such as gas heat, pressure, and tooling speed to optimize product quality and minimize defects.
- Monitor real-time machine performance and troubleshoot issues to maintain efficiency.
- Glass Forming & Defect Detection
- Carefully inspect each batch for defects, including micro-cracks, bubbles, uneven surfaces, warping, or contamination that could affect safety and compliance.
- Utilize visual and automated inspection tools such as machine vision system, magnifiers, light tables, and digital measurement equipment to detect small imperfections.
- Ensure finished products meet pharmaceutical industry regulations, including FDA and GMP standards.
- Process Monitoring & Troubleshooting
- Identify and resolve irregularities in the glass forming process that may contribute to defects.
- Work closely with maintenance teams to schedule preventive maintenance and avoid equipment malfunctions.
- Document and communicate any repeated defect patterns to engineering and quality teams for root cause analysis.
- Quality Control & Documentation
- Conduct detailed inspections during and after production using calipers, gauges, micrometers, and other precision tools.
- Maintain accurate quality logs, production reports, and records of defects for process improvement.
- Work with the Quality Assurance team to implement corrective actions and improve defect detection processes.
- Safety & Compliance
- Adhere to all safety guidelines, including PPE usage, hot glass handling protocols, and machine safety procedures.
- Follow Good Manufacturing Practices (GMP) and Standard Operating Procedures (SOPs) to maintain a controlled production environment.
- Ensure compliance with all pharmaceutical industry standards for glass packaging.
- Continuous Improvement & Team Collaboration
- Provide feedback on ways to reduce defects and enhance efficiency in the glass forming process.
- Collaborate with engineers, quality inspectors, and supervisors to implement process optimizations.
- Stay updated on new technologies and advancements in glass forming and defect detection techniques.
Qualifications & Skills
Education & Experience:
- High school diploma or equivalent required; technical training in CNC machining, glass manufacturing, and/or hot working glass.
- Minimum 2 years of experience related material fields by which operating a glass forming machines or working in highspeed glass manufacturing systems.
- Prior experience in thermal forming of similar materials within the glass family.
Technical Proficiency:
- Ability to and can demonstrate the core competency, which will result in the proper formation of a medical pharmaceutical vial upon a customer vial forming machine.
- Ability to detect small defects such as micro-cracks, inclusions, and dimensional irregularities using both visual and precision tools.
- Strong understanding of glass forming techniques, the plastic flow properties of glass, and its thermal processes (annealing, tempering).
- Familiarity with automated and manual inspection equipment such as light tables, lasers, dimensional and cosmetic camera systems.
Soft Skills:
- Highly detail-oriented with excellent visual acuity and the ability to focus on minute defects.
- Strong problem-solving and troubleshooting skills to address production issues.
- Effective communication and teamwork skills to collaborate with quality and production teams.
- Organized and self-motivated to ensure consistent quality control without direct supervision.
Physical Requirements:
- Ability to stand for extended periods while operating and monitoring machinery.
- Good hand-eye coordination and fine motor skills for small component inspections.
What we offer
Total rewards package with compensation
Healthcare
Wellness
Disability coverage
401k match
EAP (Employee Assistance Program)
PTO (Paid Time off)
Holidays
