Machine Setter

Summary

Set up a variety of similar type operations to components to produce customer specification. Plan and perform a variety of work functions to maintain equipment in efficient operating condition. Make changeovers as necessary; repair breakdowns as quickly as possible to minimize downtime. Use a variety of hand tools and gauges to make machine adjustments and check conformance of parts to specifications. Perform routine daily and weekly checks on machines to assure proper maintenance and meet safety requirements. Responsible for training operators within the department.

Responsibilities

• Certify operators according to quality/customer requirements.
• Know and follow SOP’s, Dimensional Control Plan’s and reaction plans. Provide leadership for team compliance with plans and procedures.
• Must understand and comply with our internal layered audit system.
• Set-up a variety of similar machines that produce a range of parts.
• Provide safety and work environment free of hazards. Repair or report any unsafe conditions.
• Manage tools, machines and parts to meet production goals.
• Responsible for department’s quality.
• Lead team to maintain machines and work areas in clean and orderly condition.
• Determine from parts produced, the extent and nature of adjustments and changes in tooling.
• Be aware of safety regulations and be responsible for the associate’s safety on each set up.
• Must be able to work with Engineering and Quality Assurance on machine capabilities studies.
• Coordinate with Production control on schedules.
• Remove, repair, replace, adjust and maintain tooling.
• Assist and support the associates by timely set-ups, repairs and material handling.
• Maintain SPC records/checklists as specified. Maintain process documentation relating to quality and productivity.
• Secure tooling from the crib and replace as necessary.
• Maintain good housekeeping in general work area.
• Perform preventative maintenance on various operations as needed.
• Overall Equipment Effectiveness (OEE) reviews, analysis and tracking within cells managed.
• Manage Machine Uptime.
• Perform Machine Changeover.
• Execute Production Planning
• Monitor Work in Process (WIP) within Cell
• Follow Process Controls
• Manage recovery plans
• Daily/Weekly Communication to Associates (Schedules, new/changes to procedures, policies, coaching/development, etc.)
• Daily Communication to Peers and during Shift transfers
• Train New Operators (Can be Setters or Sr. MO)
• Certify Operators and Document
• Train Sr. Machine Operators, Certify and Document
• Model cooperation and teamwork
• Train MO's on Gaging
• Train MO's on PLEX (traceability) and reinforce behaviors
• Ensure Product conforms to quality standards
• Record Quality Issues (NCR's and CAPA's)
• Complete Daily Quality and Layered Quality Audits
• Identify Quality Issues
• Reinforce 5S (housekeeping) behaviors
• Analyze and classify Scrap Daily , by Shift
• Train Associates on Safety Procedures
• Investigate, record and prepare safety incident reports. Eliminate and reinforce safety behaviors
• Ensure a safe working environment
• Police PPE procedures
• Understand what tooling is being consumed and react to abnormalities
• Ensure PM Schedules are complete
• Repair and Troubleshoot equipment
• Inventory Accuracy at the Cell Level
• PLEX Training
• Manage Cycle Counting
• Troubleshoot PLEX issues and fix mistakes

The above are principal responsibilities and do not identify all duties inherent in the job

Experience and Education Requirements

• 1-3 years machine operation experience
• 3-5 years Powder Coat Painting experience preferred
• HS Diploma or GED

Competencies – Knowledge, skills and characteristics/behaviors

• Reading, writing and mathematical level necessary to competently perform job duties
• Must have a mechanical background; setter experience preferred
• Product knowledge
• Gaging
• SPC

Additional Notes

• Position requires the ability to lift, bend, good hand dexterity, visual inspection and some manual handling not to exceed 35 pounds.