Job Summary
The RD&E 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 technician will use scientific tools/approaches to investigate, develop, and document the process parameters, provide hands on process 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
- Skilled in identifying, diagnosing, and resolving problems with machinery (low and high voltage electrical circuits, pneumatic and hydraulic equipment and .PLC (Programmable Logic Controls) or processes to minimize downtime and improve efficiency.
- Supports the RD&E during troubleshooting of complex/critical processes or equipment using 6-Sigma statistical tools (DOEs, Process Capability, Sampling, Hypothesis testing, etc.); includes data collection and analysis from development process runs; transforming the data to product specifications which includes CTQs.
- 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.
- 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 manufacturing to scale up process from RD&E to production.
- Performs and documents preventive maintenance on the all equipment, including servo motors and drives.
- Keeps up to date on thermoforming equipment and process technology.
- Demonstrates ability to understand technical drawings, process flow diagrams (PFDs), instrumentation diagrams, and equipment manuals.
- Familiar with continuous improvement processes, able to suggest adjustments or improvements to enhance efficiency and reduce waste.
- Assists in training Setup Mechanics/Operators.
Safety
- Comply with the EH&S Policy and applicable regulatory and company EH&S rules and requirements.
- Report to supervision conditions or practices that are either unsafe or that may adversely impact the environment, to ensure prompt resolution of potential hazards.
- Attend scheduled EH&S training program.
- Actively support the organization's efforts to meet or exceed EH&S goals and plans.
- Recommend 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 use of personal protection equipment (PPE).
Product Safety and Quality
- Follows Product Safety and Quality standards.
- Follows GMP's in regard to 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.
- 5 years of experience in plastic processing, preferably thermoforming.
- Strong technical skills in thermoforming, tooling, materials, product design, and affiliated processes including secondary operations and automation. Statistical analysis using Excel or Minitab is preferred.
- Ability to define problems, collect data, establish facts, and draw valid conclusions. Experience with Lean Six Sigma tools preferred.
- 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.