Molding - Thermoforming Machine Operator

Polytainers Inc-posted about 2 months ago
Full-time • Entry Level
Lee's Summit, MO
501-1,000 employees
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Reporting to the Molding Shift Supervisor, the Thermoforming Operator is responsible for performing functions associated with thermoforming operations that result in exceeding Polytainers safety, quality and delivery targets. He or she collects operating data for the purpose of conducting on-line adjustments to products, instruments, or equipment and troubleshoots technical issues.

  • Extruder, Thermoforming Machine, Molds and Parts Handling Equipment
  • Responsible for the operation, and maintenance of sheet extrusion, thermoforming lines and associated equipment/tooling.
  • Maintain correct blend of raw material through operation of automated blending equipment.
  • Perform sheet extrusion machine setup, including setting up extruder parameters, die gap and calendar roll to ensure sheet production is consistent and on gauge for the given production run.
  • Complete tooling and insert changes with precision, and speed (without compromising safety) to ensure quality and attainment goals are met.
  • Purge and re-start extruder and thermo-former with machine parameters already set.
  • Shut-down machine for schedule down
  • Adhere to SOPs and JBS pertaining to TF operation
  • Make sure thermoforming machines are set up to meet productivity and efficiency goals for each and every job.
  • Start-up any extruder/thermoforming machine without a saved set-up.
  • Setup and/or calibration of complex, servo-motorized parts handling units. Maintain, troubleshoot and make adjustments if needed for proper functioning.
  • Cleaning and Basic Maintenance
  • Daily cleaning, preventative maintenance (minor), organization and daily upkeep of extrusion equipment, thermoforming equipment, tooling, auxiliary equipment and instrumentation. Includes die cleaning, roll cleaning, and screen changes for the extruder.
  • Perform minor equipment/tooling repairs as required. Interface with maintenance personnel, as well as tooling/equipment suppliers, to address larger equipment and tooling issues.
  • Completely tear down, clean and rebuild complex thermoforming tools for the purpose of preventive maintenance and minor repairs.
  • Follow lockout / tag out procedure anytime maintenance work needs to be performed on the machine.
  • Perform daily machine/ mold cleaning and keep records
  • Perform basic machine/ automation equipment maintenance.
  • Perform machine hopper filter, magnet and extruder screen pack cleaning per schedule.
  • Clean the machine, platforms and surrounding areas clean of oil, parts and dirt.
  • Documentation
  • Maintain master set-up sheets for each mold; assist the engineer in developing appropriate set-points and tolerances.
  • Document all critical process parameters in PPMS.
  • Record running and deviations of machine process parameters in set-up sheet
  • Provide detailed documentation on corrective actions taken to resolve process/quality/production issues, assist supervisor with root cause analysis storyboard.
  • Complete metal contamination check list at beginning of each shift
  • Complete the Machine Operator Shift Report during the shift.
  • Complete the extruder/thermoforming/parts handling/mold checklist upon completion of cleaning and inspection.
  • Perform data entry operation into data collection system. (SPC)
  • Periodically review and sign off new documents released in ensur Doc Control
  • Quality/ Troubleshooting/Technical Support
  • Have critical awareness of what to watch for while job is in process; dimensions, fits, cosmetics, flaws, etc.
  • Maintains adherence to quality of product standards including trending trays, cycle time, and safety requirements.
  • Program thermoforming equipment for all heat, pressure adjustments, timing of automatic tooling movements and machine function sequences to achieve desired wall thickness, in specific areas of thermoformed parts.
  • Perform equipment adjustments within the guidelines of the process master to meet production and quality expectations (i.e. Adjust machine at console to correct deviations from program specifications).
  • Assist with and/or perform complex troubleshooting to resolving on-the-job technical problems and non-conformance issues to improve attainment and quality.
  • Identify and communicate mold/machine problems to Maintenance
  • Supports test runs for new business, provide feedback to engineering for improvements in tooling design.
  • Processes and Policies
  • Perform line clearance when there is a product change
  • Perform front line quality by visually inspecting parts as soon as they come off the machine
  • Manage last off samples and manage trending tray parts
  • Measure parts using basic instruments such as weight scales, calipers etc. to ensure in quality process. Record measurements and interpret SPC charts to keep the production process within limits.
  • Achieve shift attainment and escalate issues that impede attainment on a timely basis
  • Communicate with next and previous shifts verbally and via thermoforming log book to understand:
  • Technical issues that affect attainment and needs continued attention.
  • Quality issues that affect attainment
  • Proactively identify and suggest ways to eliminate hazards, correct unsafe acts or conditions, ensuring health & safety policies are followed
  • Enforce lockout / tag out procedure anytime maintenance work needs to be performed on the machine
  • Always comply with plant safety and SQF policies, use appropriate PPE while performing various duties
  • Maintain area 5S
  • Identify product at risk and escalate to Shift Supervisor
  • Participate in continuous improvement projects
  • Educational Requirements: High school diploma, GED, or equivalent
  • Minimum Experience/Field: 3+ years’ experience in plastic sheet extrusion and/or thermoforming equipment and processing; experience in both preferred
  • Courses Required: N/A
  • Computer Skills: Must be computer literate, with basic skills such as data entry, word processing, spreadsheets and e-mail.
  • Additional Certificates/Diplomas: Diploma from a plastic training institute or equivalent, technical school certification and/or trade school experience is preferred
  • Licenses/Permits Required: N/A
  • Physical Requirements: Ability to lift more than 50 pounds. Ability to carry more than 50 pounds. Ability to stand, walk, and climb for prolonged periods of time. Ability to reach above shoulder height and below waistline.
  • Communication Skills: Fluent in English with good verbal and written communications skills
  • Additional Education/Experience/Skills: Strong technical and manufacturing background. Strong knowledge and proven experience trouble shooting thermoforming and/or extrusion processing and tooling. Training in and troubleshooting experience with electromechanical, hydraulics, automation and pneumatics preferred. Experience with food packaging applications is preferable and SQF knowledge preferred. Strong mechanical aptitude with ability to Pass Mechanical Aptitude Tests.
  • Ability to anticipate and handle challenging situations effectively, seeking input and involving others when possible
  • Consistently uses good judgement while decision making, analyses problems from different angles to seek alternatives before determining best solutions
  • Demonstrates a strong sense of urgency, assuming responsibility without being asked in order to achieve results
  • Ability to operate electrical and electronic controls
  • Ability to read machine manuals and utilize information for troubleshooting
  • Crane, Tow-motor and skyjack training preferred.
  • Experience in tool making or tool shop is an asset.
  • Past involvements in continuous improvement projects/5S/ six sigma projects will be an asset.
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