Process Technician Levels I - IV

Posting Date: 07.28.2020

Status: Hourly

Department: Production

Reports to: Plant Manager

Job Summary:

The Process Technician is responsible for overseeing the production process as it relates to machines and automation. They work closely with key departments, other Process Technicians, Cell Managers and Plant Managers to maximize efficiencies, troubleshoot problems and keep machines running at optimal levels.

Duties and Responsibilities:

  % Time Level I % Time Level II % Time Level III % Time Level IV Essential/ Non-Essential  
Level I
1. Complete basic start- up process after receiving sign-off from Set Up Technicians that their work has been completed. 45 E
2. Keep Process Adjustment Log updated at all times. 10 E
3. Verify Tech notes, production folder, operator instructions, wiring, hot runner control hook-ups and labels from scales. 20 E
4. Verify that all safety procedures and regulations have been addressed prior to machine start-up. To include: ensuring that the machine is properly guarded, that work stations are properly cleaned and set up, and that proper Lock Out Tag Out procedures have been adhered to. 15 E
5. Work with Tool Room to coordinate basic mold repairs and preventative care. 10 N
Level II - (Apprenticeship Completion Level)
6. Complete duties and responsibilities of previous level as needed. 40 E
7.  Troubleshoot basic issues on robots or equipment. 20 E
8. Make approved process adjustments to keep machine running at optimal process/cycle time or to satisfy quality criteria of the parts. 15 N
9. Diagnose and solve rudimentary molding issues. To Include: wet material, worn check ring, warp and dimensional issues. 25 E
Level III
10. Complete duties and responsibilities of previous level(s) as needed. 20 E
11. Responsible for ensuring that all facets of molding machines and their ancillary equipment are set to recommended standards, troubleshooting and resolving molding issues and making adjustments during the molding process. 40 E
12. Set up robots and make rudimentary end of arm tooling (EOAT). 10 E
13. Start any mold without a process sheet, design robust process and identify rudimentary tooling problems. 10 E
14. Initiate corrective actions when non-conforming molding conditions occur. 5 N
15. Work with Scheduling, Set Up Techs, QA, Scales and Labor Supervisors to ensure that information is shared with the appropriate departments regarding start-ups and shutdowns. 15 E
Level IV
16. Complete duties and responsibilities of previous level(s) as needed. 10 N
17. Responsible for coordinating and continually reassessing the machine and automation needs for the job at hand, tool qualification and debug, trials and customer interaction. Applies SIM principles to achieve optimum process conditions. 40 E
18. Work closely with various departments and employees to maximize efficiency and verify that customer requirements are being met. To Include: Working with Labor Supervisors to coordinate minimal labor requirements, Tool Room to maximize tooling efficiency, Engineers to find solutions for problematic tooling issues and Scheduling to ensure best economic run and Customer Service to coordinate on-time customer delivery. 30 E
19. Train lower levels and associated personnel with regards to the intricate details of the mold, parts, quality requirements and customer expectations. 10 N
20. Assess company documents such as Cost Sheets, Corrective Action reports and daily production reports to find potential cost savings and efficiency benefits. 10 E
The above statements are intended to describe the principal functions of the position. They are not intended to encompass all duties. There may be additional duties assigned by your supervisor based on business needs.

Qualifications:

MINIMUM QUALIFICATIONS:
  1. A High School Diploma or GED and 2+ years of manufacturing experience.
  2. Set up Certification and/or successful completion of internal Apprenticeship program.
  3. Familiarity with engineering grade resins and microprocessor controlled machines, as well as setting up machines, programming and troubleshooting equipment.
  4. Successful completion of the Process Tech Level I certification
  5. Level II or above: Must have two or more of the following:
    • Completed the apprenticeship
    • Completed a minimum of 1 year on an off shift with minimal supervision
    • Certified as a Setup Tech Level II, Automation Tech, Machine Maintenance Tech or other applicable Tessy recognized certification
  6. Level III and IV:  
    • Have a working knowledge of SIM qualifications and trialing protocol.
    • Ability to work with minimal supervision
    • Possess an attention for detail with a high degree of accuracy.
    • Advanced computer experience/proficiency
    • Advanced problem-solving skills capable of solving problems involving several variables in working situations
    • Ability to test and systematically determine root cause of molding issues
    • Ability to represent Tessy in front of customers in a professional manner
PREFERRED QUALIFICATIONS:
  1. Previous production related training/certifications while at Tessy.
  2. College degree and/or relevant coursework.

Competencies:

Individuals should posses the following competencies to perform the job successfully.
  1. Communicates effectively in oral and written communications. Translates technical and/or procedural requirements into information that internal or external customers will understand.
  2. Demonstrates functional and technical skills by understanding how profitability is impacted within their area of responsibility and the company as a whole.
  3. Engages and inspires others by taking the time to build effective relationships with all levels.
  4. Implements and manages change by clarifying new processes and continuously providing communication to support change. Recognizes areas for improvement and takes actions to implement those improvements.
  5. Solves problems effectively by considering alternative solutions and possible consequences and takes into account other perspectives before making decisions. Anticipates problems and plans for contingencies.
 

Working Conditions:                                

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. The employee is frequently exposed to work near moving mechanical parts, vibration and an environment with moderate noise levels.  Exposed to work near or on hot and cutting surfaces. May be required to work in a controlled environment requiring special garb (ex. coats, hairnets, and facial hair guards), gloves and prohibiting specific items.
 

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 through our interactive process to enable individuals with disabilities to perform these essential functions. The employee must:
  • Be able to move body through different positions to allow safe maneuvering in and around machines.
  • Be able to adhere to all safety procedures and practices.
  • Be able to adhere to Good Manufacturing Practices (GMP) while utilizing tools, computers, and safety devices to efficiently complete assigned work.
  • Have the ability to work in a standing position on an occasional to frequent basis is required when performing job. However, the duration may be up to the scheduled work hours.
  • Be able to walk, squat, crouch, stoop and bend forward/sideways without aids/assistant devices on occasional to frequent basis.
  • Occasionally required to climb steps and ladders.
  • Be able to push and pull with moderate to heavy force.
  • Must be able to perform with hands, fine manipulations, forceful exertions, gripping, pinching and finger pressing.
  • Have sufficient strength and movement in upper body/arms and hands to perform repetitive forward reaching.
  • Be able to seize, hold, pinch and grasp items typical of this job with good dexterity with both hands.
  • Have good eye-hand coordination.
  • Have the ability to lift, lower and carry up to 55 lbs. on an occasional basis (1/3 of workday) and up to 20 lbs. on a frequent basis (2/3 of workday).
  • Have specific vision abilities required by this job include: color and shading discrimination, close vision, distance vision, peripheral vision and ability to adjust focus.  Must possess sight and hearing senses or by the use of prosthetics that enable these senses to function adequately.
  • Be able to correctly orient/layout parts and tools using spatial reasoning and relation problem solving.
Based on the weight and frequency of material handling and required non-handling activities, the typical day-to-day job demands of a Process Technician Levels I - IV carry the physical demand rating classification of Heavy. This rating is set forth by The United States Department of Labor. *Please Note: Physical demands vary by job title, plant location, and product design.
   

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