Extrusion Technician Lead- GC in Greencastle, Indiana at Phoenix Closures Inc

POSITION SUMMARY:

Provide process leadership, guidance, and direction of all activities related to standard extrusion process setups, new product qualifications, optimization of processes for key product quality characteristics (runs experiments), overall process stability, increasing line speed and solving complex extrusion problems.

Assist management with identifying opportunities for equipment and process improvements; and with implementing and evaluating equipment and processes changes.

Provide training and assist in the skills development of personnel assigned to work in extrusion.

To operate a high temperature plastic extrusion line to produce close tolerance triple layer plastic foam

Monitors and adjust process to produce quality finished rolled goods.

Optimize the extrusion to produce quality material at the lowest cost; to identify causes of production problems such as tooling, machinery, material, or human error, and initiate their repair; to improve quality and/or reduce cost. Provide a wide range of Safety functions to facilitate the efficient operations of the organization. This is a Safety Sensitive Position.

Assist management to monitor and coordinate all day-to-day activities and functions of the Extrusion department.

Assist manager in establishing standardized practices and improving the overall competitiveness of the operating unit;

Promotes advanced quality planning activities, assists in the review of product and process setup, monitors and guides automation and maintenance activities related to extrusion machine and extrusion performance.

ESSENTIAL FUNCTIONS:

• Order materials to specified work center;
• Loads material; cleans out hoppers; performs color changes;
• Sets temperature controllers on machines; sets up jobs based on set up sheets; sets knives for slitting;
• Lace up the line with the extruded sheet of hot melt to the winder:
• Manually cut over and start new winder rolls:
• Lifts finished rolls from machine; packages rolls and requests warehouse pickup;
• Uses lift to clear trim removal system;
• Uses hand-held measuring devices to check slit width on finished rolls, and sheet thickness. Die cut and weigh samples to calculate density.
• Monitors production;
• Maintains deviation record;
• Identify nonconforming material and sort and disposition appropriately:
• Segregates scrap material; moves scrap to reclaim room for reprocessing;
• Support the reclaim equipment and process to convert scrap material back into pellets:
• Relieves other employees during breaks;
• Backup for other shifts; Covers for absences/vacations on other shifts;
• Follow all GMP guidelines;
• Adheres to all safety rules, procedures, and Code of Conduct;
• Completes necessary documentation for all assigned machines;
• Follow manufacturing work Order (BOM);
• Monitor and adhere to all company and governmental policies, laws, and regulations;
• Organizational development through employment, training, and employee relations;
• Provide for employee safety and health with administration of all company and governmental safety
• standards and practices;
• Maintain quality standards through quality programs/procedures, GMP, IMS standards, and food safety
• requirements, policies, and procedures;
• Coordinate day-to-day operations;
• Adhere to annual and long term operational/labor objectives;
• Communicate plant maintenance issues to appropriate designates to aid in the efficient operations of
• the facility;
• Recommend/implement engineering changes to processes and standards;
• Coordinate with Scheduling department on schedule;
• Monitor, track, & report all production of extrusion with the addition of scrap produced;
• Assist in customer complaint resolution, reduction, and prevention;
• Communicate all critical information and delegate appropriately,
• Resolve production problems through analysis and evaluation of machines, tools, and associated equipment to identify the source of problems and recommend a resolution;
• Analyze tooling by evaluating its condition, recommending necessary repairs;
• Train extrusion employees in the discipline of plastic extrusion processes and various job functions;
• Any other duties as assigned;
• This is a safety sensitive position;
• Uses computer to perform various ERP requirements.
• Uses computer to send/receive emails
• Use walkies to safely transfer rolls/scrap.

OTHER RESPONSIBILITIES:

• Attend Safety, Quality, and CIT Meetings as available.
• Responsible for following all Safety Rules, policies, procedures and work instructions;
• Responsible for following all Food Safety related policies and procedures.

EDUCATION AND TRAINING:

• Minimum High School diploma or equivalent;
• Mechanical aptitude;
• Good mathematical skills;
• Basic computer skills
• Scissor Lift training and maintaining license.

EXPERIENCE:

• 5+ years in a plastic production environment desired; extrusion machine operating experience desired.
• Must be familiar with large processing equipment and GMP.

PHYSICAL DEMANDS:

• Pushing or Pulling (1-50 lbs. typically at a day) – transporting gaylords; cleans screws; moving finished
• production
• Lifting or Carrying (1-50 lbs. typically at 15 - 40% a day) - lifting and moving finished production
• Simple Grasping (typically at 15-40% a day) - measuring widths and thickness; weighing samples
• Firm Grasping (typically at 0-40% a day) - cleaning screws, loading hoppers, transporting materials to production floor, moving/lifting finished production; clearing trim removal system; setting knives
• Fine Manipulating (typically at 15% day) - set ups, checking widths and thickness, weighing samples

EQUIPMENT USED:

• Hand tools, calculator, micrometer, scales, computer, Kentucky Gauge

CONTACTS:

• Extrusion Manager; Extrusion Techs and Operators; Production and Maintenance Supervisors; other Management and hourly associates.

SUPERVISION/BACKUP:

• Reports to Department Manager