Machine Operator, Thermoforming

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Reporting to the Molding Shift Supervisor, the Thermoforming Machine Operator is responsible for performing functions associated with thermoforming operations that result in exceeding 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.

**POSITION RESPONSIBILITIES**:
Thermoforming Machine, Molds and Parts, Handling Equipment
- Responsible for the operation, and maintenance of thermoforming lines, and associated equipment/tooling
- Perform machine setup, including setting up parameters, cutting dies and raw material to ensure production is consistent 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 restart thermo-former with machines parameters already set
- Shut-down machine for schedule down
- Adhere to SOPs and JBS pertaining to operation
- Make sure thermoforming machines are set up to meet productivity and efficiency goals for each and every job
- Start-up any 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 equipment, thermoforming equipment, tooling, auxiliary equipment and instrumentation. Includes die cleaning, roll cleaning
- 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 preventative 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
- Clean the machine, platforms and surrounding areas clean of oil, parts and dirt
- Documentation
- Maintain master setup 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 checklist at beginning of each shift
- Complete the Machine Operator Shift Report during the shift
- Complete the thermoforming/parts handling/mold checklist upon completion of cleaning and inspection
- Perform data entry operation into data collection system
- Periodically review and sign off new documents released in ensure 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
- Programs 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, callipers 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 need 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
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