Sr Injection Molding Process Technician

Position Summary:

The role of a Process Technician is to set molds and start production/molding, respecting objectives set in terms of Quality, Cost and Delivery.

Responsibilities:

The main missions of the role are to:

• Work with injection molding machines and secondary equipment, on tooling issues to reduce downtime and improve efficiency.
• Monitor process and product quality while tooling runs.
• Maintain and improve Quality.
• Work with Process Engineering to reduce downtime, scrap and improve process efficiency.
• Participate in improving tool changeover times, by using SMED; improve EOAT (end of arm tooling) change over time and improve color changeover time.
• Identify molding problems due to tooling problems and report them to Supervisor.
• Participate in maintaining tooling and equipment thru Preventive Maintenance Program.
• Record downtime and scrap and changeover time
• Able to addresses minor processing issues. .
• Work flexibility in order to meet customer demands and needs.
• Work flexibility in order to meet customer requirements.
• Assist with any additional tasks as assigned by the company.
• Work safely with and during mold changes, color changes, and any movement with cranes and robot operations by using all required PPE.

   Mold changes:

• Primary task of the Process Technician is to do mold changes and production series changes
• SMED (single minute exchange of Dye)/ Quick Changeover experience
• Operate overhead crane up to 50 ton in size
• Assessing conditions of quick couplings and magnetic platens.
• Knowledge of setting up, operating crane, control tool balancing and differentiating which tools to use during mold changes (maximum load permitted for the slings; maximum load permitted for the eyebolts)
• Understanding of and consistent use of mold straps
• Understanding of Hydraulic and water connections and proper usage
• Use of Magnetic Platens

Robot Knowledge:

• Robot experience (Sepro and Engel models usage preferred)
• Able to operate Robot including start, stop, and navigating the robot properly
• Perform End of Arm tool changes and troubleshooting experience to improve part grip and robot / IMM communication.
• Make adjustments to vacuum cups, grippers, part presence sensors
• Ability to learn how to set pick, home and deposit positions
• Safely operate the Robot in Manual or Auto Modes

Materials:

• Basic Understanding of Polymers and Resins
• Experience specifically with the following materials: Polypropylene (PP), TPO, ABS, PCABS, Nylon, & Glass and Mineral filled PP.
• Basic Hopper and Dryer operations as power ON/OFF; filter cleaning and material removal.
• Understanding of which materials require Drying
• Ability to determine if a material has been dried or not when processing
• Strong knowledge of Injection Molding Machine mounted blenders for self-coloring or dilution of glass fiber.
• Knowledge on feed systems operation and trouble shooting.
• Experience with color concentrate blending and troubleshooting with material.

Processing:

• Knows the basic parameters affecting the part quality and the cycle time.
• Can adjust the barrel temperature, injection parameters, closing / opening parameters and cores movements.
• Can adjust parameters to help troubleshoot quality issues including but not limited to flash, short shots, burns, flowlines, pressure lines
• Can adjust or use machine parameters to identify small maintenance problems
• Ability to complete short shot (Fill) studies
• Can assist in press validation runs

Injection Molding Machinery:

• Can verify and recall a mold program.
• Knows the machine start-up and shut down procedures.
• Operates the mold opening and closing, clamp and unclamp of the tool, the injection unit movements and purging material for color change or cleaning purposes.
• Can perform the machine preventative maintenance for level one and two (PM 1 & 2).
• Can start the machine in semi-automatic or in automatic with robot.
• Understanding of water and hydraulic systems including valves, sensors, etc.
• Ability to operate TCU and chiller set points and faults.

Dye/Tool:

• Can locate the core quick couplings; the core electrical connectors, the mold cooling quick couplings, the sequential injection quick couplings, the sequential injection electrical connectors; and indicate their specification and assess their condition.
• Can locate and operate the cooling valves and other thermal auxiliary equipment.
• Can connect and disconnect the mold electrical connectors for hot runner power and thermocouples.
• Can perform the mold preventative maintenance for level one and two (PM 1 & 2).
• Can understand all mold functionality and internal movements and the risk associated of any wrong movement or wrong sequence of steps.
• Can troubleshoot hydraulic valve gates
• Can determine issues with lifters, pins, rib read through, etc. affecting part quality

Assembly support:

• Simple problem diagnosis and correction excluding electrical cabinet interfacing.
• Work collaboratively with maintenance on problem identification and solutions.

Position Specifications

Authorities:

• Designate process technician (within SMED team) to complete C/O duties
• Request C/O assistance from Sr. Process Tech (Gap Leader) to complete on target
• Select operators to remove gates and take to regrind process as well as compactor
• Authority to stop before proceeding if an unsafe condition is met