Sr. Machine Operator

Amcor•Victoria, TX

1d•Onsite

About The Position

The Operator Job Family includes jobs in Twist-tie, Converting, Roll Stock and Remill and includes three (3) levels; an entry/trainee level, a working level and a senior/lead level. While there are many duties in common among all Operators, there are also some duties and responsibilities applicable to jobs assigned to specific areas. This job description includes all departments and describes the differences between each level of effort. With the exception of Remill Operators, all other Operators will be expected to cross-train and be competent in all areas of Production to include: Twist-tie, Converting and Roll Stock. All Operators should be able to work in any section with any equipment and may be rotated to any section/area. Under the supervision of the Production Supervisor/Team Lead, the Operator is responsible for achieving daily production goals and performing the duties and responsibilities outlined below.

Requirements

High School diploma or GED.
1-2 years hands on manufacturing experience working with mechanical/electrical machinery.
Blown film industry experience preferred but not required.
Observes safety and security procedures; Determines appropriate action beyond guidelines; Reports potentially unsafe conditions; Uses equipment and materials properly.
Follows all ISO processes and procedures as established for the plant.
Is dedicated to providing the highest quality products and services which meet the needs and requirements of internal and external customers; is willing to re-engineer processes from scratch; creates a learning environment leading to the most efficient and effective work processes; looks for ways to improve and promote quality; demonstrates accuracy and thoroughness; monitors own work to ensure quality.
Focuses on solving conflict, not blaming; Maintains confidentiality; keeps emotions under control; relates well to all kinds of people, up, down and sideways, inside and outside the organization; builds appropriate rapport; builds constructive and effective relationships; uses diplomacy and tact; can diffuse even high-tension situations comfortably.
Asks for and offers help when needed.
Continues to seek solutions when none seems apparent.
Takes responsibility for own actions; Keeps commitments; Commits to long hours of work when necessary to reach goals; Completes tasks on time or notifies appropriate person with an alternate plan.
Ability to read and interpret procedure manuals, specification sheets and other product documentation.
Ability to write simple reports and instructions.
Must be able to understand and write in English.
Speaks clearly and persuasively in positive or negative situations; demonstrates group presentation skills; participates in meetings.
Identifies and resolves problems in a timely manner; Gathers and analyzes information skillfully; Develops alternative solutions; Works well in group problem solving situations; Uses reason even when dealing with emotional topics.
Balances team and individual responsibilities; Exhibits objectivity and openness to others' views; Gives and welcomes feedback; Contributes to building a positive team spirit; Puts success of team above own interests; Able to build morale and group commitments to goals and objectives; Supports everyone's efforts to succeed.
Basic mathematical skills to be able to understand simple mathematical concepts such as percentages and ratios; Ability to read weight scale and tape measure and/or ruler to perform quality checks.
General knowledge of computers in order to complete assignments on Percipio and access Sharepoint, JDE, QSI, Web Eff and other relevant plant software.
Ability to define problems, collect data, establish facts, and draw valid conclusions.
Ability to interpret an extensive variety of technical instructions in mathematical or diagram form.
Good electrical/mechanical understanding and troubleshooting skills
Able to identify the various resins, their properties and uses.
Skill using a variety of hand tools, electrical tools and other power tools.
Ability to perform basic math functions such as addition, subtraction, percentages, etc.
Employee must be able to drive a forklift and must have 20/20 vision with corrective lenses.

Nice To Haves

Experience with Microsoft products (Word, Excel and Power Point) highly desirable.

Responsibilities

Follows all Company policies regarding safety, quality and attendance.
Performs duties in a safe manner and report all observed safety hazards to the Production Supervisor or Production Manager.
Must participate in Safety programs; turn in one safety card weekly.
Must participate in monthly Safety Topic as well as pass monthly assessments.
Ensures a quality product through regular quality checks, by reading and verifying line orders and spec sheets.
Responds to Packers/Lead Packers, QA, or other Operators when quality issues arise.
Reports any out of spec product to the Senior Operator or Production Supervisor immediately.
Maintains a neat and orderly work area; meets plant and department housekeeping standards.
May be assigned additional housekeeping responsibilities throughout the plant as needed to maintain a clean and orderly work space.
Correctly starts up extruders; starts up lines; threads up various equipment with film.
Participates in employee driven teams to address scrap, quality, safety or other production related issues.
Must participate in and pass assessments for Annual Operator Training
Assists Operators with extruder start-ups (i.e., pulling poly from the die, bringing up the bubble, knifing out the die.)
Threads up equipment with film (i.e. winders, folders, bag machines).
Threads up the tower with rope.
Learns to conduct QA checks during startups and assists/learns to make modifications to line as needed; ensures correct product is running on line and in accordance with product specifications.
Changes the formula percentages on blenders according to the Traveler Report and verifies that the blender makes correct batches.
Changes percentage formulas, changes to the new color formula and zeroes out the scale blenders.
Enables and/or disables hoppers sets fill time (in seconds) for hoppers.
Learns to trouble shoot blender issues (i.e. flapper valves, vacuum leaks, etc.).
Identifies when the vacuum pump filter is dirty and replaces it with a new one.
Identifies when the screen pack is dirty, prepares the screen pack to be changed, and replaces the screen pack with a new one.
Identifies when the sock sleeve on stabilizer is worn and replaces it with a new one.
Assists Operators with start-ups.
Threads up equipment with film and draw tape.
Using correct gloves and PPE at all times.
Assists Operators with roll changes when replacing film and/or conducting a product change
Change out draw tape spools and know that there are various sized spools.
Learn to adjust pinners and help tape pinners in bag machine and draw tape module, clean pinners.
Identifies when a bleed/vent slit blades, hole punch claw, seal bar tape, perforation knives, drive belts, or other parts are dirty or worn; replaces seal bar tape with new tape.
Assists Operators with extruder start- ups.
Completes a roll cutover when film diameter is reached, when conducting product change or after a line start up.
Identifies when the slitter blade, fly knife, vacuum pump filter are dirty or worn and replaces with new ones.
Makes adjustments to the A-frame, gusset boards, guide sticks, to ensure conformance with width specifications.
Utilizes grinder to prepare non conforming product for processing.
Operates a fork lift truck to unload and load pallets, scrap film trucks, boxed resin trucks.
Follows procedures requiring LOTO of any trucks.
Operates a guillotine to prepare non conforming product for processing.
Maintains grinder in proper working order by removing melt down and jams.
Completes forklift safety checklist; fills propane tank on forklift.
Verifies scrap production by reviewing a variety of report
Learns how to perform a color change and how to operate a color feeder.
Replaces the extruder filters and the chiller filters.
Assist Operator II on perf knife change and die cleaning
Assists in giving breaks to Packers/Lead Packers on the lines as needed.
Learn the basics of resin: where it comes from, terminology of resin, how to read the silo scales equipment components / functions.
Learn housekeeping importance and responsibilities.
Learn terminology used in production process such as FPM (feet per minute); EEF and MEEF and how they are affected, PPLH (pounds per labor hour) and understand how it is impacted.
Learn to connect resin hoses.
Learn to effectively and safely use the tools required on the line.
Learn to read and understand a Traveler report.
Assists more experienced Operators and learns to track daily scrap.
Know location of Utilities(air and water cut offs) and how to operate and adjust
Notifies Senior Operator when production and/or quality issues arise.
Replaces filters on bag winder, bag machine, draw tape module and unwind.
Learns the basics of resin: where it comes from, terminology of resin, how to read the silo scales equipment components / functions.
Learns the basics of resin: where it comes from, terminology of resin, how to read the silo scales equipment components / functions.
Learns to make Gauge adjustments and read a Profile.
Learn to identify the various Die/Screw sizes and impact on machine output, and quality issues,
Learns to make Gusset adjustments and complete an inspection report
Learns to operate an electric pallet jack and complete an inspection report
Learns to safely operate band saw in order to cut down cores.
Inspects equipment for proper operation.
Conducts QA checks during startups and makes modifications to line as needed; ensures correct product is running on line and in accordance with product specifications.
Identifies when equipment needs repair, cleaning or adjustment and replaces, cleans or adjusts as needed.
Enters work requests in work order system when Maintenance involvement is needed.
Makes adjustments to perforation knives, air horn, turret to align in accordance with specifications
Sets up and monitors ink jet printers
Prepares and conducts product changes on automation equipment.
Cleans vision systems on automation
Performs profile tests, read analyzes and interprets a Fourier Analysis and a Polar Plot to ensure film is at correct gauge throughout.
Reviews finished film samples, meter weights and lay-flat measurements to ensure product meets specifications; makes modifications to the line as needed.
Identifies when die pin is dirty and writes up work order for Maintenance to clean.
Enables/disables, sets fill time for hoppers to
Uses Sorema extruder to process re-ground non-conforming product; starts extruder from both a warm and cold start up; properly shuts down extruder as needed.
Identifies when equipment needs repair; changes screens on Sorema extruder, canister filter socks, head cutter blade.
Runs labels for each work order.
Cleans and dries resin silos as needed.
Unloads railcars and hopper trucks into silos; taps railcars as needed.
Performs profile tests, reads, analyzes and interprets Fourier Analysis and Polar Plot to ensure film is at correct gauge throughout.
Troubleshoots extruder and film issues such as gauge, die lines, melt fractures bubble instability, tear offs, telescoping rolls, overlaps and takes appropriate action to correct.
Completes blender reports for assigned shift to keep track of material usage; reports any issues to Production Supervisor.
Tracks downtime reasons and scrap using spreadsheets and WebEff.
Trains and assists less experienced operators.
Trouble shoots film issues such as tear offs, telescoping rolls, flare outs, overlaps, etc.
Performs line start QA check, makes modifications as necessary and approves line for packing.
Tracks downtime reasons and scrap using spreadsheets and WebEff.
Trains and assists less experienced operators.
Print daily production schedule and/or Traveler Report to verify that correct product is running on the line and to identify future product changes.
Tracks downtime reasons and scrap using spreadsheets and WebEff.
Complete required reports to keep track of production and/or quality issues.
Trains and assists less experienced operators.
Maintains accurate inventory of resin by reviewing production needs and ordering needed resin in a timely basis.
Conducts periodic scrap and resin inventories.
Keeps track of available inventory.
Changes grinder blades as needed
Trains and assists less experienced operators.

Benefits

Medical, dental and vision plans
Paid time off, starting at 40 hours per year for full-time hourly employees, may vary by location
Company-paid holidays starting at 8 days per year and may vary by location
Wellbeing programs & Employee Assistance Program
Health Savings Account/Flexible Spending Account
Life insurance, AD&D, short-term & long-term disability, and voluntary benefits
Paid Parental Leave
Retirement Savings Plan with company match
Tuition Reimbursement (dependent upon approval)
Discretionary bonus program (initial eligibility dependent upon hire date)