Injection Molding Process Technician

Summary

The Process Technician performs duties in accordance with training, written and verbal instructions, policies, practices, and procedures. General tasks revolve around verification of mold setup, materials, process, auxiliary equipment, end-of-arm-tooling, packaging, and documentation.

Daily direction is taken from the Lead Process Technician.

Essential Duties And Responsibilities

· Full competency to backfill and/or assist Material Handler and Setup Technician is required.

· Conduct all activities safely to prevent personal injury and/or property damage, while actively monitoring actions of other employees to report risky behavior.

· Follow all safety instructions, LOTO procedures, and correct or report all safety concerns immediately upon discovery.

· Communicate with employees and visitors in a professional, positive, and helpful manner.

· Maintain housekeeping standards by following established 5S program.

· Obtain and maintain forklift certification to move materials and equipment as necessary.

· Utilize IQMS to accurately and effectively…

o Determine current production details (Work Order, BOM, Hours to Go, etc.)

o Determine upcoming order details (Change of Resin, Change of Colorant, etc.)

o Plan and communicate with others to reduce changeover times.

o Place molds in “Out of Service” as needed and document requested mold repair.

o Search for BOM information when resin or packaging information needs verification.

o Update Downtime Descriptions as they change (Setup or Ready to Start).

o Follow special instructions.

· Prestart verification expectations…

o Physical attributes of the mold and auxiliary equipment setup

1. Acceptable hose protection utilizing plastic guarding

2. Examine entire mold and platen area for any setup tools that may have been left behind accidently

3. Grinder is well aligned to accept runners where applicable and necessary hoses have solid connection and correct routing to blender, or regrind container

4. Picker jaws or robot grippers are aligned

5. Part containment is adequate to prevent loss

6. Any extra requirements for cleanliness are met

o Program settings for press and auxiliary equipment match documentation

1. Human Machine Interface (HMI) accurate

2. Dryer temp accurate and where required, moisture analyzer result posted at press and is acceptable to start

3. Confirm Water, Steam, Oil heater setpoint and temperature stable

4. Blender settings are correct

o All required documentation is present and matches mold number…

1. Work Order

2. Process Sheet (matching tool number)

3. Process Log

4. Startup Completion Checklist (initialed/dated)

5. Visual Inspection Directions

6. Packaging Directions

7. Sample Label Form

8. Material containers, hopper, and dryers all have resin identification

o End-of-arm-tooling (EOAT) matches instructions and is installed correctly

o Line clearance 100% complete (review in, under, and around entire area)

o Review of mold tags for comments of importance like Engineering requests

o Test the torque settings for mold protect and adequate toggle or lock up

o Ensure cavity pressure transducers are connected and reading correctly

o Verify the date code pin for accuracy

· Follow Master Molding I or II training based on your previous education courses

o Use caution during initial startup such as low pressure and low speed (SOFT START)

o Utilize D2 concepts when necessary to troubleshoot basic fill issues

o Upon stabilization, verify pressure graphs match previously established process, observe material feeding process for correct operation, determine if any further adjustments are required to picker/robot, alarm settings are entered and turned on to limit risk of reject conditions being missed.

o Check actual cycle time against the quoted standard cycle time and make (in tolerance) adjustments to bring down to standard or below, without sacrifice to part quality.

o Apply any fine-tuning necessary for 100%-part containment, this includes rejected parts bin/area to maintain an organized and safe environment.

o Complete the entire Setup Completion Checklist and collect 1 part from every cavity (Full Shot) to measure basic dimensions in the quality lab.

NOTE: If missing initials for prior tasks are blank, it is your responsibility to examine these tasks, ensure completion, and initial. No submission is approved without initials or N/A when appropriate for every task.

o Using the control plan, the Process Technician conducts specified inspections using the referenced devices and documenting results as directed.

NOTE: When a Quality Technician or Lead is available, they will finish advanced measurements and approve/reject both parts and the setup completion Checklist form signing off and placing in a bin for later retrieval and placement back at the press by the Process Technician.

· When alerted to reject conditions such as flash, short shot, discoloration, out-of-specification dimensions, etc., systematic troubleshooting is required to correct.

· Ability to troubleshoot malfunctions on auxiliary equipment is also required within the safety of your knowledge. Components or systems posing personal risk of electrical shock, pressure impacts, high temperature, or lacerations should not be touched without previous training.

· Mold (in press) preventative maintenance is also required while an order is running. These expectations may include safely…

o Cleaning parting lines (Using mold cleaner spray applied with a clean wipe)

o Inspecting cavities and vents for removal of any gassing residue build up

o Verification of shoulder bolt tightness

o Verification of smooth slide motion, and slide pins are not gawled

o Greasing leader pins lightly

o Operating ejector system to listen for binding and look for worn pins

· Follow machine shut down procedures as specified which may include…

o Close receiver/hopper throat gate

o Retract carriage and purge barrel empty

o Turn off heating and cooling systems (barrels, nozzle band if equipped, dryer, water-steam-oil units, etc.)

o Turn off conveyors, grinders, task lighting, runner separators, and home robots

o Leave each press area safe and clean, free of all debris (resin pellets, molded parts, runners, purge patties, water, oil, etc.).

· Effective communication is critical in this role due to the training, Q&A, and demonstration of correct operating methods and expectations for less experienced employees.

QUALIFICATIONS

· High school diploma or equivalency, required

· 5 years of experience as an IM Setup Technician required

· 1 years of experience as an IM Process Technician required

· 3 years of experience as an IM Process Tech or Sample Tech preferred

· 3 years of experience with RJG

· Strong attendance, communication, and interpersonal skills

· Excellent mechanical and electrical aptitude

· Excellent troubleshooting skills

Job Type: Full-time

Pay: $23.00 - $28.00 per hour

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Health insurance
• Paid time off
• Vision insurance

Schedule:

• 8 hour shift
• Evening shift
• Night shift
• Overnight shift

Application Question(s):

• Describe your compensation expectations

Experience:

• RJG: 1 year (Preferred)
• Plastics injection molding: 1 year (Required)

Shift availability:

• Night Shift (Required)
• Overnight Shift (Required)

Ability to Commute:

• Germantown, WI 53022 (Required)

Work Location: In person

Salary : $23 - $28