Die Technician II

Pridgeon & Clay • Grand Rapids, MI

1d • Onsite

About The Position

The Die Technician 2 works with die build or production teams to follow company designated processes to build, tryout, upkeep and maintain dies in an exemplary manner according to the company quality policies. This role involves working with progressive, transfer, compound, hand-feed or feinblank dies, and requires skilled machine shop operations, including welding. The position also involves assisting with project management, detailed documentation, and problem-solving. Candidates will also be responsible for training and mentoring other Die Technician trainees in the Career Path program, demonstrating leadership in a team environment. The role requires computer literacy, the ability to lift 50 pounds, and adherence to safety regulations, including wearing appropriate safety glasses.

Requirements

• High school diploma or GED
• Completion of an Associate's Degree in Tooling & Manufacturing (or similar program) or completion of a college-based or apprenticeship-based Tool & Die or Technician program or certificate
• Ability to train, teach, and assess other Die Technician trainees in the Career Path program, working well and leading and mentoring in a team environment
• Experience in the prototype or tool & die trade, specifically making, repairing, setting up, trouble-shooting and running dies
• Proven ability to work with progressive, transfer, compound, hand-feed or feinblank dies.
• Skilled in machine shop and machining operations, including welding
• Proven ability to assist with managing projects and resources effectively, including detailed documentation on tooling issues and component prints
• Excellent problem-solving and trouble-shooting skills
• Ability to pass written and practical tests to obtain company hi-lo and crane license
• Proven mechanical inclination, general math and manufacturing knowledge, and trouble-shooting skills through standardized assessments
• Computer literacy
• Ability to lift 50 pounds
• Must not wear tinted safety glasses, or have a need for tinted safety glasses
• An excellent work record, including attendance

Responsibilities

• Complete necessary paperwork for die books, tool biographies, and EAM (if applicable), and ensure stock replenishments.
• Optimize and communicate knowledge base, including documenting die build and tool tryout issues, and ensuring CAD data and die books are updated.
• Maintain proper inventory and organization of the die sensor tool chest.
• Maintain inventory and organization of all die detail components and sensors within defined inventory locations.
• Document hours and work activity daily in the Electronic Asset Management (EAM) system using proper repair codes.
• Prioritize and organize die repairs, work orders, components, tracking, parts, and tooling information in data systems (Kanban, EAM, Jasper).
• Complete and submit Maintenance/Repair/Operations (MROs) to set up stock replenishments in EAM.
• Create die changeover instructions, die repairs, and end of run issues, ensuring CAD data and die books are updated, and Managers are notified of any issues.
• Ensure all instructions and documentation are saved electronically in the correct location.
• Use stock lists generated by the die design team to ensure all die components are present, and notify Manager or a lead Die Technician if they are not.
• Visually compare die components with CAD data to ensure accuracy, including heat treating process (if necessary).
• Notify Manager or lead Die Technician of any heat treating and altering of any inaccurate die components.
• Drill, set, and attach necessary parallels.
• Assemble, set, and dowel necessary die component details, drilling and mounting blocks in proper locations, ensuring trim steels, punches, and embosses are properly placed and meet tolerances.
• Assemble all remaining die component details from stock lists and notify Manager or lead Die Technician to verify timing.
• Load dies with die springs and nitrogen cylinders.
• Perform die tryouts, including setting dies, clamping die bolsters, loading coils, and feeding coil stock.
• Ensure dies are built accurately (t-slots, cone locators), and shut heights and feed heights are correct.
• Create smart pac cams for feed rate, sprayer timing, sensor timing, shut height, and overloads.
• Alter servo transfer systems to set fingers or fine blanking presses, as needed.
• Notify a lead Die Technician of any component changes, including ejector pins, screws, dowels, and stripper pads.
• Operate machine tools to spot, grind, and finish hardened mill blocks to verify specific dimensions.
• Build, assemble, install, and adjust fingers in presses per design or instruction.
• Prepare to install sensors into dies and fingers, verifying replacement is needed, retrieving and reviewing designs and diagrams, and organizing and labeling wires.
• Identify, select, install, and replace sensors, guarding, and valves based on function, application, and information from diagrams.
• Ensure sensors, wires, boxes on rails, valves, cylinders, and hoses are protected.
• Document items needed for installation, including sensor and pin location and work performed, via pictures, EAM, and sensor installation sheets.
• Wire, verify, and adjust sensors, valves, and cams for proper clearances and timing to ensure optimal performance.
• Install, plumb, and secure sprayers and sprayer components in dies properly, as well as chutes, keeping clear of all moving parts.
• Work with press technicians and process engineers to verify newly built dies are accurate, shut heights and feed heights are correct, and dies are timed out properly.
• Notify designer of any component changes, including ejector pins, screws, dowels, and stripper pads.
• Repair dies, including cleaning components, changing out cracked or damaged tooling, sharpening and shimming, welding, grinding, cutting hardened components, inspecting and sharpening trims, punch, and die steels, polishing forms, prepping backup and changeover tooling, and checking parts on the fixture.
• Program transfer systems to optimally transfer parts from station to station.
• Build and repair fabricated components using the MIG welder.
• Troubleshoot automatic and hand-feed tooling and set-ups in-press.
• Use data (EAM, operator observation, visual inspection, measurement, etc.) to problem-solve needed die changes.
• Use Smartpac and press controls modifications to ensure presses operate optimally.
• Validate process parameters and notify the proper operations group to enter system deviations when applicable.
• Alter or adjust die components to ensure die operations produce optimal parts.
• Combine problem-solving methods with data, information from technicians/operators, and part analysis to determine specific die changes needed.
• Apply continuous improvement concepts to dies and the changeover process via preventive maintenance and corrective actions.
• Make adjustments to improve part quality and tool life, achieve cost savings, fix overlooked areas, simplify dies, and identify potential cost savings for pitch and width reductions.
• Ensure backup tooling is correct and present.
• Identify and attempt to eliminate areas of waste for better efficiency and overall production needs.
• Anticipate die and operation problems and work to eliminate them before they happen.
• Participate in and support lean initiatives such as continuous improvement events and problem-solving events, identifying and eliminating all types of waste.
• Suggest and implement ideas to increase personal and departmental efficiency.
• Communicate potential cost savings to other Technicians and Manager.
• Participate in 8D and 5-Why problem-solving teams, Plan-Do-Check-Act (PDCA) events, die improvement reviews, and die reviews.
• Make necessary sample parts and submit them to the metrology lab for layout.
• Use and maintain quality tools such as calipers, micrometers, height gages, solid squares, pin gages, dial indicators, Joe blocks, 1-2-3 blocks, machine parallels, angle plates, sine plates, V-blocks, precision vices, protractors, feeler gages, radius gages, and telescoping gages.
• Verify tooling components for accuracy before use, including using the layout on tooling detail prints.
• Verify that parts produced are manufactured according to requirements; document as needed per control plan.
• Examine forms for thinning and hard mark areas, implementing tooling changes as needed.
• Use available quality data (Statistical Process Control, Coordinate Measuring Machine checks, control plans, visual inspections) to verify that parts meet quality standards.
• Consistently adhere to and support company policies and procedures, including ISO, TS 16949 and safety regulations.
• Safely use hi-lo and cranes, maintaining licenses, maintenance schedules, and inspection sheets.
• Use overhead crane to dry run dies, checking for interference between upper and lower die shoes, and notify a Die Tech I if interference is found.
• Follow all safety procedures, including Personal Protective Equipment (PPE), controls, safety devices, lock-out/tag-out, use of coolants, and die block procedures.
• Identify potential safety issues and take appropriate action.
• Ensure environment is free of avoidable risks, and report concerns immediately, taking appropriate action to rectify and resolve.
• Organize and maintain personal work area and tool room per 5S standards.
• Notify Team Leader if repair or replacement of machinery or equipment is needed.
• Effectively communicate with co-workers and management personnel to enhance teamwork and communication initiatives.
• Provide necessary, accurate, and timely feedback of all pertinent information to co-workers and management.
• Train new and existing employees on all aspects of Tool & Die build and repair, using Training Checklists as a guideline.
• Mentor new and existing employees in areas of needed skill development as appropriate to job duties and requirements.
• Know tooling and capability run dates, and communicate any information that would prevent those dates from being met.
• Consistently exhibit appropriate attendance habits, working the hours necessary to perform the job, and being at the work station on time at the beginning of shift and after breaks, working until the end of shift.
• Accept instructions and duties in a positive manner, while treating all co-workers with dignity and respect.
• Seek clarification for complete understanding, and process information for job independence and elimination of waste.
• Assist in maintaining company values (Integrity, People, Customers, Ownership, We Can If....Safety) daily, through thoughts and actions.

Benefits

• Premium medical and prescription coverage starting at just $5.00 per week for employee coverage
• Dental
• Vision
• 401(k) with company match
• Tuition reimbursement

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Education Level: Associate degree