Tool Maintenance

Job Description
Title: Tool Maintenance Department: Engineering
Job Analysis: November 23, 2004
Status: ExemptNote: Statements included in this description are intended to reflect in general the duties and responsibilities of this classification and are not to be interpreted as being all inclusive.RelationshipsReports to: Set-up / Tool Maintenance Manager and Tool Maintenance Lead
Subordinate Staff: N/A
Other Internal Contacts: Management, Engineering, Maintenance, Warehousing, Production, Scheduling, and Customer Service
External Contacts: Customers and VendorsJob SummaryThe Tool Maintenance person is responsible for maintaining, repairing, and changing over of all the forming molds and trim dies in this facility from one product to another product. He or she will be required to troubleshoot tooling problems at the line, and determine the best course of action to correct the problem. The tool maintenance person is expected to work safely and follow all GMP rules. He or she will be responsible for proper housekeeping, and organization of the tooling department. The tooling maintenance person will be required to fill out a daily log book of the work performed on the forming molds and trim dies and communicate the status of the department to the following shifts. The tool maintenance person is expected to be able to operate a milling machine, lathe and surface grinder to repair damaged tooling, fabricate simple parts, and sharpen small dies.Job Responsibilities and DutiesWorking safely is the #1 responsibility for all employees at Mullinix. If you do not know how to operate or work safely on any machine or in any area, DO NOT continue until you have been trained properly to do your job!Note: All duties are to be considered ESSENTIAL unless followed by an “N” for Non-Essential.
A. Safety1.Ensure that safety is the top priority throughout the department2.Work according to all Safety and GMP rules
3.Shut down electrical devices and / or main power supply properly
4.Shut down air supply properly
5.Use safety blocks and gear box wrenches when working on tooling.
6.Yearly recertification in the Lock out / Tag out program
7.Strive for safety goal of zero accidentsB. Quality1.Ensure tooling is set-up properly to produce quality parts.
2.Report any problems discovered with tooling that may affect the quality of the parts produced from the tooling.
3.Assist production with tooling problems that are affecting the quality of the parts.
C. Duties1.Follows the plan for the tool and die changeovers.
2.Maintains all components of tooling. (Repairs damaged threads, removes broken fasteners, repairs minor nicks and dings in cavities or plugs, sharpens small dies as required)
3.Completes tool and die changeovers in the standard allowed time frame.
4.Cleans, tags, and properly puts away all tooling components after a tool or die set change over is complete.
5.Follows standard tooling practices during tooling changeovers to make sure changeovers are done actually and correct.
6.Prepares, and stages tooling for changeover employees.
7.Follows SOP formats for Tool and die changeovers.
8.Notifies tooling manager, or tooling lead when documents in the tooling department are not up to date or accurate. (Tool set-up book, SOP’s)
9.Makes sure tooling components are in perfect running condition, Clean, sharp, no damage, before installing them into a tool or die set.
10.Initiates the repair of damaged and dull tooling to be sent out for repairs.
11.Notifies tooling manager, or tooling lead when tooling supplies or tools are needed.12.Fills out log book of work performed on molds and communicates the status of their projects to the next shift.
13.Operates Fork truck to move tooling from work area to shelves.
14.Operates Overhead boom to move tooling in work areaD. Housekeeping
1.Keeps the tooling area in a neat and orderly condition2.Maintain housekeeping by applying 5S principles3.Maintain Good Manufacturing Practices (GMP’s)E. Scheduling
1.Completes daily assignments so that the production schedule can be maintained.G.Facilitate Continuous Improvement1.Apply Root Cause Analysis methods for problem solving
2.Apply Lean Manufacturing concepts (i.e., SMED, Kaisan, 5S, etc.)
3.Communicates thoughts or Ideas that would improve the tool changeovers to the tool maintenance manager
H. Employee Relations1.Works well with all other tooling employees
2.Supports needs of Change over employees
3.Supports needs of production Supervisor.J. Engineering support1Assist engineering with tool problems.
Knowledge, Skills, and Abilities1.Must be able to follow set-up book to locate and set-up forming tools and die sets for the correct products.
2.Ability to operate standard arc welder to make repairs to broken baskets
3.Ability to repair damaged threaded holes
4.Ability to remove broken fasteners from threaded holes.
5.Must be able to use micrometers, calipers, inside mics.
6.Ability to operate the milling machine and surface grinder and lathe to repair damaged tooling, or fabricate simple parts.
7.Must understand the function of the tooling during the thermoforming, and trimming sequence of operation.Physical Characteristics1.Withstand extreme heat temperatures occasionally
2.Climbing on or in machines for setup or troubleshooting
3.Work in a noisy environment
Educational or Certification Requirements1.Tool and die experience preferred
2.High School Diploma, GED, or the equivalent required
Other Requirements1.Ability to operate and run a Thermoformer and trim press a plus.
2.Demonstrate mechanical aptitude3.Furnish tools for personal use in the tooling department
4.Pass the Nowlin Selection Process that demonstrates the employee has efficient skills in reading, mathematics, and observations.
Machines, Tools, and Equipment Involved1.Hoist 12. Jergens inserts
2.Chains and straps13. Taps
3.Fork lift14. Drills
4.Ladders15. Dry Ice Blaster
5.Cleaning Supplies16. Drill press
6.Hand tools17. Grinders / Buffer
7.Measuring devices18. Thermoformer
8.Milling Machine19. Trim Press 9.Surface grinder20. Extruders
10.Heli-coils21. Other 11.Computer Equipment
REQUIREMENTS
* clean, disassemble, and reassemble forming molds and trim dies
* change over molds and dies to different products
* repair and maintain molds and dies as needed
* fabricate parts or fixtures to maintain tools and auxiliary equipment
* diagnose and correct tooling problemsCandidates must have:
* basic tool maintenance skills (drilling, tapping, reaming, repairing damaged threaded holes, and removing broken fasteners)
* Mechanical aptititude
* Problem solving capabilities
* Self-motivationCandidates must be able to work a 12 hour shift. (Average of 15 days per month) Day shift hours are 6am - 6pm and Night Shift hours are 6pm - 6am. 12 hours schedule is outlined below:48 hours one week; 36 hours the following week
48 hour week works: Monday, Tuesday, Friday, Saturday
36 hour week works: Sunday, Wednesday, ThursdayWe offer the following:
* Night Shift Bonus of .50 per hour
* Fully paid medical insurance for the employee ($10 per week for family coverage)
*Work only 15 days per month (full-time)
*Opportunity for advancement
*Team Environment
*Vacation/Holiday Pay
*Tuition Reimbursement
*401(k)