Job Description

Description

Essential Duties and Responsibilities

• Owner of the new tool and equipment qualification and validation process (OQ/PQ Process) and ensuring there is compliance with the process and that the results are properly documented and communicated to the appropriate personnel to ensure the effective transition of new tools and equipment into production.
• Establishes processes, procedures, and techniques for starting up and shutting down tools and production equipment that can be utilized by the manufacturing floor to minimize quality problems and maintain a high level of efficiency.
• Provides education and training on injection molding and related manufacturing technologies to the technical manufacturing staff. Ensures the technical manufacturing staff has the appropriate skill level to perform their job effectively and efficiently.
• Establishes troubleshooting guidelines, processes, and techniques for addressing production issues with the emphasis on identifying and addressing the root cause.
•  Acts as the team leader for resolving problematic tools and equipment problems so that they are capable of producing a quality product on a consistent basis.
• Assists the Mold Technician's during absences, vacations, emergencies, or heavy workloads.

 Responsibilities

• Owner of the new tool and equipment qualification and validation process (OQ/PQ Process) and ensuring there is compliance with the process and that the results are properly documented and communicated to the appropriate personnel to ensure the effective transition of new tools and equipment into production.
• Responsible to continuously improve the process of establishing injection molding processes. Implementing cavity pressure sensor technology, software to identify machine / process issues and a process monitoring system to ensure all molding processes are controlled and monitored at all times.
• Establishes an optimum and sustainable process that processes a part that is within specification and documents via the Master Cycle Sheet (UPS). Identifies critical setup parameters and ensures they are included in the Manufacturing Inspection & Control Plan (MICP).
•  Main member of the corrective action team to find root causes to issues and identify corrective actions to mitigate/eliminate the issues in production.
•  Properly documents all appropriate inputs and outputs of the OQ/PQ process, including the qualification of equipment.
•  Where required, or appropriate, performs a DOE or Capability Study and documents the results.
•  If required, makes recommendations for changes to obtain a properly functioning mold, fixture, or equipment. Engages the appropriate functions and team members to implement and verify the changes.
•  Proactively interfaces with the Project Team to ensure that the results from the OQ/PQ process are communicated, issues are identified, and corrective actions have been established to ensure an effective transition of mold into production.
• Accountable for proper reporting of material, including scrap, for any OQ/PQ that they are managing.
• Responsible for the accurate reporting of downtime for those stations in which they are working on an OQ. This means from the time the job is started through the completion. This does not include weekends where presses are scheduled down.
•  Identifies critical setup parameters and ensures they are included on the In-Process Control Plan.
• When appropriate, walks through process startup with the Mold Technicians to ensure understanding.
• Documentation is a high priority for this position. This will be a data-driven position that will support issues by data and not meaning-making.
• Detailed Mold Preventative Evaluations (MPE) that document any issues or concerns regarding a mold while in the molding presses.
• Maintenance Work Orders that request repair or review of a concern regarding a piece of equipment.
•  Validate BOMs and report discrepancies feedback to the Engineering department when a production line cannot meet BOM specifications. Engineering is the keeper of BOM records.
•  Reviews Process Change Logs completed by the Mold Technicians to identify and resolve mold issues, machine issues, material issues, or a lack of understanding of how to process the mold.
• Establishes processes, procedures, and techniques for starting up and shutting down tools and production equipment that can be utilized by the manufacturing floor to minimize quality problems and maintain a high level of efficiency.
• Works in conjunction with the Engineering Manager, Production Manager, and Quality Leader & Technical Specialist to understand current and future process needs and strategic changes and makes the necessary plans to address those needs.
• Establishes the policies, procedures and training for proper setup, startup and shutdown of jobs. Works with staff members to ensure that processes are understood, efficient, and effective. If necessary, works with the Foreman if there are concerns regarding compliance.
• Works in conjunction with Engineering and Quality to establish OQ/PQ policies and procedures for efficient and effective qualification and validation of tools and equipment.
•  Provides education and training of appropriate staff members on the principles and techniques associated with the OQ/PQ process to ensure proper execution and results.
• Provides education and training on injection molding and related manufacturing technologies to the technical manufacturing staff. Ensures the technical manufacturing staff has the appropriate skill level to perform their job effectively and efficiently.
•  Assist with the interviewing and qualification of candidates for the Mold Tech, Setup, and Process / Manufacturing Engineering functions.
• Identifies external technical training sources, such as RJG and Paulson, for improving the skills and knowledge of the various technical manufacturing functions and works in conjunction with the Production Manager to establish formal skills development plans for each of the staff members.
• Creates and delivers in-house education and training materials for improving the overall efficiency and effectiveness of our injection molding operations. This includes providing hands-on or one-on-one training where necessary.
• Establishes troubleshooting guidelines, processes, and techniques for addressing production issues with the emphasis on identifying and addressing the root cause.
•  Works in conjunction with Production, Quality, and Engineering to establish guidelines and protocols for troubleshooting production tooling, equipment, and process issues and trains the appropriate personnel.
• Where possible, establishes and documents troubleshooting methods for common problems to facilitate the timely and consistent resolution of common problems.
• Where possible, leverages third party troubleshooting guidelines, techniques, and processes.
• Acts as the team leader for resolving problematic tools and equipment problems so that they are capable of producing a quality product on a consistent basis.
• Works in conjunction with the tool room, quality, engineering, and the appropriate manufacturing staff to identify and resolve chronic tooling and equipment problems.
• Schedules and facilitates meetings, assigns action items, and follows up on action items to ensure timely resolution of issues.
• Works with the team to identify and improve upon preventive and predictive measures to minimize unplanned events.
• Assists the Mold Technician's during absences, vacations, emergencies, or heavy workloads.
• Will perform other duties and responsibilities as assigned by supervisor.

Requirements

• Minimum of 15 years of experience in an injection molding environment with at least 10 years in a process technician, process engineer or related position.
• Formal training and certified as a Master Molder Level 3 is highly desired.
• Experience in tooling and cavity pressure molding is highly desired.
• A firm understanding of thermoplastic materials, their characteristics, and impact on process and quality
• Must have experience with quality assurance tools and techniques for problem solving and continuous improvement such as 8D, Poke-Yoke, Kaizen, PFMEA and Process Control.