Process Technician

Job Summary

The Process Technician supports the development and enhancement of prototype manufacturing processes utilizing thermoforming contact-heat and pre-heat machines to ensure a smooth transition of new products/processes to production. This involves the installation, setup and troubleshooting of thermoforming tools as well as the development of thermoforming processes (recipes). The Process Technician will use scientific tools/approaches to investigate, develop, and document process parameters, provide hands on troubleshooting and the collection and analysis of data. This role will also identify processing improvement efforts and suggest design changes that could increase the overall process windows for transfer to production.

Essential Job Responsibilities

To perform this job successfully, an individual must be able to perform each essential functions/duty satisfactorily. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Other duties/functions may be added or assigned.

Operations

• Fluent use of hand tools, and power tools, to work on thermoform machines, and fabricate machine parts necessary to maintain and update machinery.
• Use of electrical meters in troubleshooting and analyzing machine problems.
• Assembles wires, insulation, and electrical components, such as timing devices, relays, solenoids and regulators.
• Installs electrical assemblies and hardware in housing.
• Tests assembled equipment for circuit continuity and operational reliability.
• Analyzes test results and repairs or adjusts equipment according to analysis.
• Records test results and writes report on fabrication techniques used.
• Calibrates instruments according to specifications.
• Perform set-ups on all thermoforming machines
• Assists in training of Setup Mechanics/Technicians, and Machine Operators.
• Understand and troubleshoot low and high voltage electrical circuits.
• Understand and troubleshoot pneumatic and hydraulic equipment.
• Perform and document preventive maintenance on the production equipment as well as on the production support equipment.
• Work with production automation equipment like robots, palletizers, case erectors and high-speed jet printers.
• Understand and troubleshoot PLC (Programmable Logic Controls), Servo Motors and Drives.
• Documents process development, adjustments and resulting data. Works with Tooling engineering to document, using ECO's, any tooling or machine modifications resulting during product or process development.
• Operates independently to define processing parameters and recipe development for new products.
• Attends Design Review meetings as part of the new product development team to provide insight and expertise in regard to the process and tool design, capability and part handling.
• Works with RD&E to scale up process from RD&E to production.
• Identifies factors that negatively affect cycle time and work towards resolving such problems.
• Monitors condition of equipment and tooling and notifies management about areas that need attention.
• Work with internal and external suppliers/partners for problem resolution to identify and execute improvements.
• Keeps up to date on thermoforming equipment and process technology.
• Must be able to 'dial in' processes to achieve product specifications.
• Must have knowledge and ability to setup form, trim, and scoring presses and install tooling.
• Keeps record of pertinent process variables for the purpose of benchmarking and improving the process.
• Coordinates with Quality to ensure product quality.

Safety

• Complies with the EH&S Policy and applicable regulatory requirements.
• Reports conditions or practices that are either unsafe or that may adversely impact the environment, to ensure prompt resolution of potential hazards.
• Attends scheduled EH&S training programs.
• Actively supports the organization's efforts to meet or exceed EH&S goals and plans.
• Recommends improved EH&S practices.
• Practices safe work habits and follows general safety procedures such as proper lifting and bending, ergonomics, proper use of equipment and the use of personal protection equipment (PPE).
• Ensures that all fall protection procedures are strictly adhered to including but not limited to the use of harnesses, platform ladders, railings, lifts, etc.
• Ensures lockout procedures are followed any time the equipment is being cleaned or maintained.

Product Safety and Quality

• Follows Product Safety and Quality standards.
• Follows GMP's regarding food contact packaging as it pertains to the employee.
• Follows IPC product defense standards and complies with all SQF requirements.

Minimum Requirements (include education, experience, special skills, licenses and/or certifications required.)

The list below represents the knowledge, skill, and/or ability required to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• High school diploma or general equivalency degree (GED) and 5-8 years of thermoforming experience. Technical background including technical school or previous technician experience. A college degree in manufacturing is a plus.
• Ability to manage multiple projects and establish priorities
• Ability to work in a fast paced, flexible environment
• English speaking. The ability to read, analyze, and interpret common scientific and technical journals, financial reports. The ability to effectively present information to stakeholders and management
• Knowledge of robotics, automation, equipment and processes in thermoforming.
• Demonstrated knowledge of SPC, DOE, geometric tolerance and blueprint reading.
• Strong communication (verbal and written), teamwork and organizational skills.
• Strong technical skills in thermoforming, tooling, materials, product design, and affiliated processes: to include secondary operations and automation; Skilled in statistical analysis using Excel or Minitab is a plus.
• Ability to define problems, collect data, establish facts, and draw valid conclusions.
• Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables.
• High degree of mechanical aptitude required.