Process Technician

Description

JOB SUMMARY:

To perform mold changes, support production startups and troubleshooting, and ensure all process parameters and machine settings are properly established and followed according to the process setup sheets, with a goal of ZERO Defects. This position will be based approximately 30% in Fraser, Michigan, with approximately 60% travel to other company facilities and customer locations to provide technical support, complete mold changes, and assist with process setup and optimization.

ESSENTIAL DUTIES AND RESPONSIBILITIES :

The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Frequency of duties, percent of time and work year may vary based on department or building assignment.

• Maximize uptime on all machine centers by proactively monitoring processes, reducing downtime, and improving production efficiency.
• Set up, start up, shut down, and troubleshoot injection molding machines and auxiliary equipment.
• Perform mold changes, including mold installation, alignment, connection of utilities, and verification of proper mold protection settings.
• Document and maintain all process parameters in accordance with Master Setup Sheets and established process specifications.
• Load, verify, and adjust process parameters including temperatures, pressures, transfer positions, cycle times, and material drying conditions.
• Monitor production processes and make adjustments as necessary to maintain quality standards and optimize machine performance.
• Respond promptly to quality concerns, operator issues, machine alarms, and process-related problems.
• Troubleshoot molding defects including short shots, flash, burns, splay, warpage, and other quality issues; identify root causes and implement corrective actions.
• Drive the reduction of scrap and non-conforming product through process improvements, corrective actions, and mold maintenance activities.
• Perform first-piece and in-process quality inspections using measuring equipment such as calipers, gauges, and other inspection tools.
• Assist in achieving quality objectives, including reducing external PPM and internal PPM performance metrics.
• Ensure all machine safety devices and features are operational, including safety switches, drop bars, interlocks, and guarding systems.
• Follow all company safety procedures, including PPE requirements, OSHA regulations, Lockout/Tagout (LOTO), hazardous material handling, and safe lifting practices.
• Operate forklifts, pallet jacks, overhead cranes, and other material handling equipment safely and efficiently when certified and authorized.
• Identify maintenance concerns and equipment issues and coordinate with maintenance personnel to support timely resolution.
• Verify material identification, lot traceability, drying requirements, and proper handling of virgin and regrind materials.
• Maintain accurate production documentation, setup sheets, process logs, downtime records, scrap reporting, and ERP system transactions.
• Participate in mold change and setup reduction initiatives to improve uptime, throughput, and overall equipment effectiveness.
• Maintain a clean, organized, and safe work environment in accordance with company housekeeping and 5S standards.
• Communicate process changes, production concerns, quality issues, and shift updates to supervisors and incoming shifts.
• Assist in training and mentoring Process Technicians, Operators, and other team members on processing standards, quality requirements, and safe work practices.
• Support continuous improvement initiatives focused on safety, quality, delivery, productivity, and cost reduction.
• Perform other duties as assigned by the Shift Supervisor or Management.

Requirements

EXPERIENCE AND EDUCATION:

• High School Diploma or GED required.
• Demonstrated ability to work effectively, efficiently, and safely in a busy manufacturing environment.
• Demonstrated ability to multitask in a fast past environment.
• Must be able to read, follow and perform tasks outlined by work instructions.
• Must pass written and performance test for operating a hi-lo.
• 5+ years’ experience in a plastics manufacturing environment performing similar duties preferred.
• Knowledge of IATF production and quality control practices preferred.
• Experience training others preferred.
• Prior experience contributing to continuous improvement and safety initiatives preferred.
• Must have forklift experience.
• Must be willing to work overtime, when required to do so.
• Must abide by all forklift safety rules.
• Minimum 2-3 years of hands-on experience in plastic injection molding and mold change operations.
• Strong understanding of thermoplastics, mold setup, tooling safety, and processing techniques.
• Familiarity with scientific molding principles (e.g., RJG, Decoupled Molding) is a plus.
• Ability to read and interpret blueprints, setup sheets, and technical documentation.
• Strong mechanical aptitude and troubleshooting ability.
• Willingness to work flexible shifts, including nights and weekends as needed.

PHYSICAL REQUIREMENTS & WORKING CONDITIONS :The physical demands, work environment factors and mental functions described below are representative of those that must be met by an employee to successfully perform the essential functions of this job.

• Ability to lift, carry, push, or pull up to 50 pounds.
• Able to stand, stoop, twist, climb and repetitively perform tasks for long periods of time (8 to 12 hours).
• Able to bend the body forward and downward while bending at the spine at the waist 45 degrees or more; bending below the waist or down toward an object on or near the ground.
• Able to work around hot molds, presses, cranes, and industrial equipment and work in tight spaces.
• Able to use hands and fingers to seize, hold, grasp objects.
• Ability to extend arms with the hands higher than the head; reaching at or below shoulder level.
• Ascend or descend ramps and/or stairs using feet and legs.
• Ability to hear, understand, and distinguish Speech and/or other sounds (machinery alarms, medical codes, or warnings). Work frequently in close proximity to machinery; noise levels are moderate.
• Close vision (distance of 20 inches or less) and ability to identify/distinguish colors.
• Hands-on role 60-80% of the time, with mixture of desk and computer duties.
• Temperature in facility can vary up to 90 degrees. Candidates must be able to perform duties in hot and cold environments.
• Able to work independently with limited supervision.
• Must be able to remain in a stationary position 50% to 100% of the time.
• Able to ascend/descend forklift and standing lift, trailers, steps, ladders etc.
• No aversion to heights
• Frequently exposed to moving mechanical parts, fumes, risk of electrical shock, and vibration.
• Frequently exposed to high, precarious places.

WHY JOIN OUR TEAM?

• Competitive hourly pay based on your skills and experience.
• Comprehensive benefits package, including employer-paid medical/HSA coverage for eligible employees who elect individual coverage.
• 401(k) retirement plan to help you invest in your future.
• Generous paid time off and company holidays so you can recharge and spend time with family.
• No-cost weekly uniform service - we take care of it for you.
• Annual boot allowance for qualified safety toe footwear to keep you safe and comfortable.
• Hands-on experience with a wide variety of molds And tooling challenges, offering continuous learning and skill development.