Powder Prep Opr I - D Shift - 7:30pm - 7:45am (4 on - 4off)

JOB TITLE: Powder Prep Opr                                                      JOB GRADE: NE07

FLSA STATUS: Nonexempt                                         DEPARTMENT NAME: Materials / Powder Prep

DEPARTMENT CODE: PDRPRD                                              REPORTS TO: Supervisor        

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I. POSITION SUMMARY

Safely operates and monitors the sifting process, which ensures that the raw materials are processed to the correct particle size specifications; safely operates and monitors the department's weighing line processes; replenishes and maintains sufficient levels of materials in the weighing silos and in the material staging areas; and safely operates and monitors the alumina and modori lines, thereby replenishing and maintaining sufficient levels of materials in the weighing silos; all of which enable the safe and efficient production of completed weigh batches, which are used in the manufacturing process

II. ESSENTIAL DUTIES AND RESPONSIBILITIES (The section is not intended to be an all-inclusive list and NGK Ceramics reserves the right to include other duties as assigned):

     Alumina/Modori duties:

A.    Checks the disintegrator oil levels and checks magnets at the beginning of each shift

B.    Monitors weighing silo levels to determine shift production requirements

C.    Verifies that the available alumina super sacks match the lot numbers on the Lot Designation Sheet (reports discrepancies to Technical Leader or Supervisor); and confirms that the panel display indicates the correct setup for the desired material silo

D.    Confirms that the hopper is clean and empty; vacuums outside of super sacks to ensure that no debris or contaminants are introduced into the hoppers or weighing silos

E.    Uses hoist to place sack on hopper; unties sack through safety door opening; and, empties sack into the hopper

F.    Verifies that raw material tanks are empty before changing to another material

G.    Confirms that the indicator lights on the computer panel display show that the correct silo is selected for the transport of the modori that is to be charged

H.    Verifies the correct material by using: color-coded identification tags, color-coded sacks, color-coded stripe through modori pieces

I.      Confirms that the disintegrator amperage is between 30-50 amps

J.     Charges the correct material by emptying sacks into the hopper or by manually placing modori pieces into the crusher

K.    Completes paperwork and enters the lot data into the company's information systems

Sifting duties:

A.    Monitors weighing silo levels to determine shift production requirements

B.    Verifies that the available raw material lot in the bulk silos match the lot numbers on the Lot Designation Sheet (reports discrepancies to Technical Leader or Supervisor)

C.    Verifies that sifter screens are in good condition prior to processing

D.    Charges and processes material lots in accordance with the company’s work instructions

E.    Checks sifter screens’ condition after each processed lot

F.    Obtains samples from processed lots for testing and lab analysis

G.    Performs sieve residue tests on samples from each processed lot to ensure that the particle size results are within specifications

H.    Notifies Technical Leader or Supervisor if sieve residue test results are outside of specifications

I.      Inputs processed lot data & sieve residue test results into the company’s information systems

J.     Takes samples to the Material Control Lab for analysis

K.    Prepares transport setup to the correct weighing silo for Technical Leader’s approval and transportation

L.     Builds, removes and replaces sifter screens and blades as required

     Weighing duties:

A.    Ensures weighing racks are clean; RFID (Radio Frequency Identification) tags are secured; and that super sacks are properly attached to the racks

B.    Verifies the current weigh batch proportions before weighing batches; operates and monitors the weighing line process and reports errors or discrepancies to the Technical Leader or Supervisor

C.    Checks weigh batch tickets to confirm that all weigh batches are within specifications; then initials weigh batch ticket and places it in the pouch of the appropriate weigh batch; staples ticket inside pouch

D.    Writes the correct body name and batch numbers on the super sacks; and ties the tops of the super sacks securely

E.    Enters data into the company's information systems

F.    Obtains samples weekly for material control analysis and records the test results into the Infinity system

     Additional duties:

A.    Works safely by avoiding forklifts; staying clear of forklift doors; using personnel doors when entering or exiting the buildings; and safely uses overhead hoists

B.    Participates in PM (Preventive Maintenance), MMOL (Machine Maintenance Operator Leader) and G5S (Global 5S: Sort, Set in Order, Shine, Standardize, Sustain) activities as needed

C.    Follows all EMS (Environmental Management System) procedures, including the disposal of waste and used materials

D.    This job has no supervisory responsibilities.

III. REQUIRED COMPETENCIES

Customer Focus. Environmental Awareness and Compliance. Functional & Technical Expertise and Computer Skills. Integrity and Accountability. Organizational Awareness. Respect and Humility. Safety Orientation. Teamwork.

IV. REQUIRED AND PREFERRED QUALIFICATIONS

A.    Required Education and/or Experience                                                    

1.     Must be able to successfully complete all required job training.

2.     High school diploma or general education degree (GED).

3.     6 month manufacturing/warehousing experience or equivalent

4.     CRC Bronze or above

5.     Certified Production Technician program completion (preferred)

B.    Required Language Skills                                                           

1.     Ability to read and interpret documents such as safety rules, operating and maintenance instructions, and procedure manuals.

C.    Required Mathematical Skills                                                      

1.     Ability to add and subtract, multiply and divide in all units of measure, using whole numbers, common fractions, and decimals.

D.    Required Reasoning Ability                                                         

1.     Ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form.

2.     Ability to deal with problems involving several concrete variables in standardized situations.

E.    Preferred Qualifications                                                  

1.     Basic MS Windows software skills.

2.     Forklift License

V. PHYSICAL DEMANDS (The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions and will be determined on a case by case basis):

1. While performing the duties of this job, the employee is regularly required to stand; walk; use hands to finger, handle, or feel; reach with hands and arms; climb or balance; and talk and hear.

1. The employee is frequently required to stoop, kneel, or crouch.

1. The employee must frequently lift and /or move up to 50 pounds.

1. The employee must successfully pass scheduled testing for respirator fitting and spirometry.

VI. WORK ENVIRONMENT

1. While performing the duties of this job, the employee is regularly exposed to moving mechanical parts; is frequently exposed to airborne particles; and occasionally exposed to extreme cold; outdoor weather conditions; and vibration.

1. The noise level in the work environment is usually moderate and occasionally loud.

VII. SAFETY REQUIREMENTS/PPE

A.    Safety shoes must be worn while on NGK property.

B.    Hearing protection is required in designated areas.

C.    Safety glasses are required in designated areas.

D.    Respirators are required in designated areas or under prescribed work conditions.

E.    Regularly scheduled testing is performed for: lung capacity (i.e. spirometry test), hearing, and respirator fit.

VIII. EMPLOYMENT DISCLAIMER

A.    This job description is not to be considered a written contract.  Employment with NGK is at will.  This means that the employee, as well as the company, is free to terminate the employment relationship at any time and for any reason not prohibited by law.  Also, this job description is not designed to be a complete listing of the tasks, duties or responsibilities that are required of the employee.

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