Process Engineer

Woodstock, IL 60098

Post Date: 03/16/2018 Job ID: b5b8a105-515d-4ee8-8864-c795092bb019 Industry: Management
Job Title: Process Engineer
Department: Production
Reports To: Production Manager
FLSA Status: Non-Exempt
Job Grade:

SUMMARY

Manage Mold Tool Set-Up Staff (Mold setters and Mold Techs) and Press Room facilities. Lead Injection Molding Projects. Create and maintain Process Documentation. Provide procing advice for injection molding equipment, facilities, training.

ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned.

Manage Mold Tool Set-Up Staff (Mold setters and Mold Techs):
Coordinates responsibilities, maintains payroll, assists with HR needs, assures training and compliance of Mold Setters and Mold Techs to established standards and procedures.

Lead Injection Molding Projects: for APQP, New project launches, Sampling Projects and Continuous Improvement Program / Projects. Create and maintain Procedures and Documentation for injection molding process such as Process Set-up Documents, Procedure check sheets and logs... Etc.

Assure Mold Set-up Staff properly prepares Plastic Resin For production.

Assure Mold Set-up Staff coordinates with Production Control and Toolroom to assure production readiness of mold. Preventative maintenance is up to date. Mold configuration is correct per Job. Assess maintenance requirements of Mold.

Assure Mold Set-up Staff coordinates with Production Control to schedule mold set-up and mold removal according to production schedule. Coordinate with Production Control to schedule operator assignments and tasks according to production schedule

Assure Mold Set-up Staff performs Mold set-up. Install Mold tool on to press and assure Press Set-up (hardware and software settings) conform to Process Set-up Documents. Hardware includes: mold tool placed, aligned and clamped to press properly; all ancillary equipment (such as dryers, auto-loaders, conveyors, thermalators, hot oilers, auxiliary controllers etc.) properly connected.

Assure Mold Set-up Staff performs Production Cell Set-up. Assure all materials and production equipment is ready for operator use. Materials include inserts and other part components to be molded into the product, packaging. Production Equipment includes sorting and collection containers, gate cutters, at press test/inspection equipment etc.

Coordinate with Mold Set-up Staff, Toolroom, QA to monitor, maintain, refine Process Set-up documents
Coordinate with Mold Set-up Staff, Toolroom, QA to monitor, maintain, and assure production part quality per Work Instructions, Control Plan, Quality Alerts. Start-up sample inspection process, Regular process checks, new production issues.

Assure Mold Set-up Staff coordinates with Maintenance to assure Press room facilities and equipment are functional and suitable for job. Provide suggestions for facilities, equipment improvements, process improvements for increased efficiency.

Interprets company policies and adheres to and assist other workers in adhering to safety regulations.
Assist in maintaining and improving workplace environment. Identify and assist to resolve workplace environment problems. Suggests plans to motivate workers to achieve work goals.

Assure Mold Set-up Staff maintains time and production records. Examples include Product book logs, Toolroom requisition...Etc.
Performs production, processing or assembly work in absence of operator/line worker.

Knowledge of the EMS, QMS policies, goals and objectives. Assist with systems based on Lean principles and practices that meets or exceeds the requirements of ISO 9000, AS9100, ISO14001, TS-16949 and all other quality standards required to serve our target markets. Assure Mold Set-up Staff Knowledge of the EMS, QMS policies, goals and objectives

Performs other duties and special projects as assigned by department manager.

QUALIFICATIONS
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

EDUCATION and/or EXPERIENCE
High school diploma or general education degree (GED); or one to three years related experience and/or training; or equivalent combination of education and experience.

ADVANCED INJECTION MOLDING EXPERIENCE
Knowledge of raw material: injection molded plastic resin, colorant, fillers. Basic Polymer concept. Thermoplastic Material family/types/classes/grades. Filler types and uses. Basic polymer behavior as effected by material and filler family/types/classes/grades. Applications and processing behaviors of plastic resins.

Knowledge of injection molding process concepts: Plastic resins processing path from hopper, through screw, into mold. Plastic part mold flow regarding resin and gas. Effects of temperature clamp pressure, injection pressure; transfer, packing, cooling. Basic flaw types and causes: flash, knit lines, splay, gas pockets, burns, shorts, contamination, warp, cracks, shrink, crawl, wrinkle. Knowledge of solutions for basic flaws. Knowledge of advanced molding concepts: 6 step scientific molding, RJG Training, Paulson Training etc

Advanced knowledge of Mold construction and effect on plastics. Materials, Components, surface finish, gate number/location. Runner system types (hot vs cold). Mold types common at AMT: (3-plate molds, hot runner, cold runner, hydraulic core ). Mold Class (SPI) identification and properties of how each run and are maintained. Experience with domestic and import molds.

Mechanical inclination with ability to handle heavy material handling equipment. Knowledge of mold setting hardware and tools. Ability to use gantry/overhead cranes, forklifts...Etc. Ability to set up automation equipment (pick and place robotics, end of arm tooling, gate cutters, automated vision inspection/protection systems).

Knowledge of how to operate Injection mold press operation. Manual operation, Load/run programs, basic machine maintenance and components of press. Create and maintain programs and output reports. Troubleshoot press hardware and software.

Knowledge of how to operate ancillary equipment usage. Thermalators, Hot Oil heaters, auxiliary controllers, dryers/loaders, conveyers... Etc. Advanced troubleshooting of ancillary equipment.

Advanced Injection Molding troubleshooting. Independently adjust process parameters and equipment alleviate major molding issues. Record all issues on setup log and offer explanation of cause for changes, changes made, and effect of change on Process Set-up and mold/press maintenance. Coordinate with Engineering, Production manager, QA, Toolroom and Manufacturing engineering to access and validate changes to Process setup documents.

LANGUAGE SKILLS
Ability to read and comprehend simple instructions, short correspondence, and memos. Ability to write simple correspondence. Ability to effectively present information in one-on-one and small group situations to customers, clients, and other employees of the organization.

MATHEMATICAL SKILLS
Ability to add, subtract, multiply, and divide in all units of measure, using whole numbers, common fractions, and decimals. Ability to compute rate, ratio, and percent and to draw and interpret bar graphs.

REASONING ABILITY
Ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form. Ability to deal with problems involving several concrete variables in standardized situations.

PHYSICAL DEMANDS
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is frequently required to stand; walk; use hands to finger, handle, or feel; reach with hands and arms; and talk or hear. The employee is occasionally required to sit. The employee must frequently lift and/or move up to 10 pounds and occasionally lift and/or move up to 25 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus.

WORK ENVIRONMENT
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is occasionally exposed to moving mechanical parts and risk of electrical shock. The noise level in the work environment is usually moderate.

RESPONSIBILITY AND AUTHORITY
Individual has responsibility and authority to carry out assigned duties.

Desired Experience:
5-10 years in injection mold set-up and press room environment desired. Experience in leadership position highly desired.

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