Setup Technician Team Lead

Position Description

Uses advanced technical knowledge to troubleshoot, adjust, set up, and support plant production equipment. Performs all duties associated with the setup of die casting equipment to produce quality products safely and efficiently.

In addition to technical responsibilities, serves as the Shift Leader, providing day-to-day leadership and coordination of employees assigned to the shift. Ensures production priorities, safety requirements, quality standards, and company procedures are followed throughout the shift. Acts as the primary point of communication between shift employees, supervisors, maintenance, quality, and other supporting departments.

Job Responsibilities

Die Cast Setup & Technical Responsibilities

• Perform die cast mold changes and cell adjustments according to the production schedule, following SMED procedures, including die setup, die connections, and correct process parameter settings to achieve and maintain production targets.
• Ensure die changes are started on time based on the production schedule and established changeover priorities.
• Verify and make corrective adjustments to dies and peripheral equipment, including hose changes, limit switch cables, cylinder changes, plunger rod changes, plunger and shot tip changes, and emergency die changes due to damage to ensure proper and continuous operation of the Die Casting Machine.
• Verify that all tools, equipment, materials, and other items required for setup are available and ready for use prior to beginning the setup.
• Move casting and trimming tools to the appropriate casting cell where the setup will be performed.
• Move all additional items required for setup to the appropriate casting cell prior to the start of the setup.
• Supervise and document all setup activities using the required setup checklist.
• Validate proper die preparation prior to performing a die change.
• Perform preventive actions and adjustments to reduce equipment downtime, scrap, quality defects, and production interruptions.
• Set process parameters for each product following every die change. Start the Die Casting Machine and verify that process parameters are correct according to the applicable part number, work instructions, and process specifications.
• Verify proper operation of equipment and tooling during startup and ensure parts meet established quality requirements.
• At the completion of setup, proceed with production startup and provide parts to the Quality Department for required inspection and approval, including X-ray approval when applicable.
• When no setup or die change is required, assist with keeping Die Casting Machines running production and addressing technical issues that may affect production.

Shift Leader Responsibilities

• Provide day-to-day leadership, direction, and work coordination for employees assigned to the shift.
• Assign employees to machines, workstations, and production activities based on the production schedule, staffing levels, employee qualifications, and operational needs.
• Communicate shift production goals, priorities, die changes, quality concerns, safety issues, and other important information to employees at the beginning of and throughout the shift.
• Monitor production activities throughout the shift to ensure production schedules, cycle times, output requirements, scrap targets, and quality expectations are being met.
• Coordinate die changes, machine setups, troubleshooting activities, and production priorities to minimize downtime and maintain production flow.
• Monitor machine downtime and respond promptly to production interruptions. Coordinate with Maintenance, Quality, Logistics, and Management when additional support is required.
• Ensure employees follow established work instructions, process parameters, control plans, quality standards, and production procedures.
• Verify that required production, quality, scrap, downtime, and setup documentation is completed accurately and in a timely manner.
• Monitor employee compliance with safety policies, required PPE, safe work practices, housekeeping requirements, and established plant procedures.
• Immediately address unsafe conditions or behaviors and report significant safety concerns, incidents, injuries, equipment issues, or hazards to management.
• Ensure employees are properly trained and qualified for assigned work. Identify training needs and assist with on-the-job training and development of employees.
• Provide employees with appropriate work direction, coaching, and feedback regarding safety, quality, productivity, attendance, and workplace expectations.
• Address routine employee and production issues during the shift and escalate disciplinary, attendance, performance, or employee-relations concerns to the appropriate Supervisor, Manager, or Human Resources representative.
• Monitor staffing and attendance during the shift and communicate call-offs, late arrivals, early departures, staffing shortages, or other coverage concerns to management.
• Assist with coordinating break and meal schedules while maintaining adequate production coverage.
• Ensure nonconforming or suspect product is properly identified, contained, and communicated to Quality in accordance with established procedures.
• Stop or escalate production when an unsafe condition, significant quality concern, equipment problem, or other condition exists that could affect employee safety, product quality, or equipment integrity.
• Support troubleshooting and root-cause activities related to equipment downtime, scrap, quality concerns, and production inefficiencies.
• Promote teamwork and professional communication among employees and assist in resolving routine work-related concerns.
• Maintain good housekeeping and organization throughout the assigned production area and support established 5S/workplace organization standards.
• Communicate production status, downtime, quality concerns, equipment issues, staffing concerns, unfinished work, and other relevant information to the incoming Shift Leader or Supervisor during shift handoff.
• Complete required shift reports and provide management with an accurate summary of significant events occurring during the shift.
• Support continuous improvement activities designed to improve safety, quality, productivity, equipment reliability, changeover time, and workplace organization.
• Perform other leadership, production, setup, and technical duties as assigned based on operational needs.

Safety Responsibilities

• ALWAYS wear all PPE prescribed for the assigned activity and ensure employees on the shift comply with applicable PPE requirements.
• Follow and enforce all company safety policies, procedures, Lockout/Tagout requirements, machine safety requirements, and safe work practices applicable to the assigned area.
• Immediately report safety incidents, near misses, unsafe conditions, and equipment hazards in accordance with company procedures.

Job Skills Requirements

• Advanced troubleshooting skills using mechanical, electrical, pneumatic, and hydraulic knowledge.
• Skill and working knowledge of tooling practices and applications.
• Strong knowledge of die casting equipment, tooling, mold changes, machine setup, and process parameters.
• Demonstrated leadership and decision-making skills.
• Ability to effectively direct and coordinate the work of others.
• Ability to prioritize production needs and respond effectively to changing production conditions.
• Strong problem-solving and troubleshooting abilities.
• Good teamwork, interpersonal, and communication skills.
• Ability to communicate effectively with production employees, supervisors, maintenance personnel, quality personnel, and management.
• Ability to coach and train employees in production processes, safety requirements, and work procedures.
• Basic computer skills and ability to accurately complete required electronic and written documentation.
• Ability to read and understand production schedules, work instructions, process documentation, quality requirements, and applicable procedures.
• Fluent in English and the primary language used in the area of responsibility and/or location, as required to effectively communicate safety, quality, and production requirements.

Education

• High School Diploma or equivalent combination of education and experience.
• Technical or vocational training in industrial maintenance, manufacturing, die casting, or a related field is preferred.

Experience Requirements

• Minimum of 3 years of technical experience in manufacturing, die casting, industrial maintenance, machine setup, or a related field.
• Previous leadership, team lead, or supervisory experience in a manufacturing environment is preferred.
• Previous experience with high-pressure aluminum die casting operations is preferred.

Physical & Environmental Requirements

• May be required to lift or carry products, parts, tools, and/or other materials of various sizes and weights:
• Frequently: 5–25 pounds
• Occasionally: 25–75 pounds
• Rarely: Greater than 75 pounds
• Ability to stand and/or walk constantly over a full work shift of 8–12 hours.
• Ability to perform occasional to frequent pushing, pulling, bending, kneeling, twisting, crawling, climbing, and/or reaching over a full work shift of 8–12 hours.
• Ability to use power and vibrating tools over a full work shift of 8–12 hours.
• Ability to operate authorized motorized vehicles and material-handling equipment as required over a full work shift of 8–12 hours.
• Ability to work in a manufacturing environment that may include exposure to heat, moving equipment, oils, lubricants, metal, and other conditions associated with aluminum die casting operations.
• Exposure to noise levels for which hearing protection is required over a full work shift of 8–12 hours.
• Must be able to work safely around industrial machinery, automated equipment, molten-metal operations, and other manufacturing processes.
• Will be required to obtain and maintain MST certification.

Benefits Include

Medical, Dental, Vision, Life Insurance, Short-Term Disability, Long-Term Disability, Paid Time Off (PTO), Holiday Pay, Birthday Pay, Anniversary Pay, and 401(k).