DPF Operator I - D Shift - 7:30pm - 7:45am - (4 on 4 off)

NGK Ceramics USA, Inc.•Mooresville, NC

5d•Onsite

About The Position

Operates and monitors the sifting process to ensure raw materials meet particle size specifications. Also operates and monitors the department's weighing line processes, maintains material levels in weighing silos and staging areas, and operates the bulk unloading process for raw materials from railcars into silos. These functions are essential for the safe and efficient production of weigh batches used in the manufacturing process.

Requirements

Must be able to successfully complete all required job training.
High school diploma or general education degree (GED).
6 months manufacturing/warehousing experience or equivalent.
CRC Bronze or above.
Ability to read and interpret documents such as safety rules, operating and maintenance instructions, and procedure manuals.
Ability to add and subtract, multiply and divide in all units of measure, using whole numbers, common fractions, and decimals.
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.
Safety shoes must be worn while on NGK property.
Hearing protection and safety glasses are required in designated areas.
Respirators are required in designated areas or under prescribed work conditions.
Regularly scheduled testing is performed for: lung capacity (i.e. spirometry test), hearing, and respirator fit.

Nice To Haves

Certified Production Technician program completion.
Basic MS Windows software skills.
Forklift License and Pallet Jack License.

Responsibilities

Monitor weighing silo levels to determine shift production requirements.
Obtain raw materials from the on-site warehouse after verifying material type and lot number.
Vacuum the outside of raw material bags to prevent debris from entering sifters or weighing silos.
Retrieve manufacturer's information from bags, position bags using a hoist, untie and attach the spout to the hopper opening, and empty the bag into the hopper.
Verify sifter screens are in good condition before processing, charge and process material lots according to work instructions, and check sifter screen condition after each lot.
Obtain samples from processed lots for testing and lab analysis.
Perform Cilas machine particle size test on samples and notify Technical Leader or Supervisor if results are outside specifications.
Input processed lot data and Cilas test results into company information systems and take samples to the Material Control Lab.
Prepare transport setup to the correct weighing silo for Technical Leader's approval and transportation.
Build, remove, and replace sifter screens and blades as required.
Check outside dust collectors and replace bags when full; clean weighing silo magnets when required.
Verify the correct order number and starting weigh batch number on the computer before starting the weighing process.
Ensure weighing racks are clean, RFID tags are secured, and super sacks are properly attached to racks.
Monitor the weighing line process, report errors or discrepancies to the Technical Leader or Supervisor, and check weigh batch tickets for specifications.
Write batch numbers on super sacks, tie the tops securely, double-stack weighed batches onto export pallets, and load onto the rack system.
Prepare cardboard box containers and place them on proper pallets; prepare weigh batch barrels for weighing by lining them with appropriate bags.
Check weigh batch tickets to confirm all batches are within specifications, secure bag tops, weigh each batch to reconfirm actual weights, and write batch data on a log before placing weigh batches in boxes.
Write enclosed batch number range on all 4 sides of box containers and body name on the front and back, place lid on filled container, tape securely, and stack boxes/pallets on the floor in sequence.
Verify body code being weighed and check computer and silo diagram levels to determine materials needed for silo filling.
Obtain raw materials from the on-site warehouse after verifying material type and lot number, and vacuum bag exteriors.
Print bar codes for each bag with correct product name, lot number, and weight; transport single bags on pallets and stage near the elevator; stage correct materials in front of silo filling stations.
Open dust collection valves at silo filling stations and select the appropriate silo for filling on the computer touch screen.
Confirm bar code ticket and manufacturer's information match the silo to be filled, and operate the hoist to lift material bags onto the silo filling station.
Scan the bar code to unlock the silo cover, remove the cover, untie the material bag, empty it into the silo, and replace the cover.
Select 'stop filling' on the computer touch screen to update inventory levels and complete paperwork for each lot dumped into the silos.
Work safely by wearing proper PPE in designated areas.
Perform system checks and setup in preparation for bulk rail material transfer.
Verify all railcar numbers in the yard.
Inspect railcars and ensure proper settings of valves and petcocks.
Verify raw material lot numbers for each incoming bulk rail material match the Lot Designation Sheet.
Prepare hoses for raw material transfer according to work instructions.
Confirm correct hose connections by examining indicator lights on the control panel.
Transfer bulk rail materials to the correct bulk silos.
Regulate blower pressure and railcar pressure during bulk rail material transfer.
Obtain material samples during raw material transfer.
Perform Cilas machine particle size test on samples obtained during raw material transfer.
Input sampling data into the appropriate QSI Infinity project.
Notify area management if particle size data falls outside control limits.
Verify railcars are empty and perform proper shut-down procedures after raw material transfer.
Adhere to 'Quiet Time Zone' procedures.
Unclog raw material lines as needed.
Work safely by avoiding forklifts, staying clear of forklift doors, using personnel doors, and safely using overhead hoists.
Participate in Preventive Maintenance (PM), Machine Maintenance Operator Leader (MMOL), and Global 5S activities as needed.
Follow all Environmental Management System (EMS) procedures, including waste disposal.