Machine Operator, 2nd shift (with $2.50 shift differential)

Wire Mill Machine Operator

2nd shift: 3:00pm-11:00pm

$21.50/hour [$19/hr base rate + $2.50 shift differential]

In order to produce and supply quality products wire is drawn to comply with internal and external customer specifications. After drawing some materials are complete while others may continue to be drawn. Wire is drawn and annealed by utilizing standard machinery, procedures, materials, people, tools, equipment and ISO/AS work instructions, assuring adherence to quality and continuous improvement standards.  Performs other duties as required but which comply with ADA.

Essential Job Functions

• Under general supervision, sets-up and operates, 1 to 10 machines. Adjusts machines to maintain continuous drawing of wire at correct speeds and prepares products for next step in production.   Sets - up production runs from work orders, production diagrams or orders and wire part number system, daily.
• Under general supervision, performs repetitive assignments involving the operation of the following machinery for the production of drawn wire:  Watkins, Herborn, Morgan Koch, Niehoffs, SE-12, M-7's New England Butt, Loos Machines, Macbee, C-16 hand cutters, Tensile Tester, Welder and Molly Tester.
• Makes standard measurements/adjustments applying rudimentary shop math calculations relative to tolerances and dimensions.  Monitors and adjusts temperature, oils, weights, product, spool changes, gauges, valves, flow rations, pressures and related controls and guidelines to ensure adherence and quality to production / product / process / specifications. Checks diameter, tensile, color and surface conditions accurately using calipers, gauges, micrometers and other routine measuring equipment. 
• Maintains operating records, production control sheets, test results and daily PSI data sheets.  Reports any malfunctions or abnormalities to supervisor/s.  Confirm, record, label, initial and date the following: part numbers, actual diameter, break strength, inspection data and SPC data, daily.
• Attendance: Regular and predictable "physical presence" on-site attendance is an essential job function and a prerequisite to perform other functions of the job.

Additional Responsibilities

• Measures and works with a variety of lubricants.
• Conducts and records preventative maintenance.  Cleans work areas and machinery.
• May measure and work with a variety of materials and chemical mixtures.  Inputs timely and accurate data into the company's computer system and databases.
• Communicates on a regular basis with supervisors, technicians and co-workers regarding the production, procedures, issues regarding the department and production.
• Involved in the training and participation of statistical process control (SPC), work teams and project teams.  May be trained in or provide training in advanced continuous improvement techniques, these include but are not limited to, facilitating work teams, computer training, authorizing, reviewing and updating work instructions, problem solving and communication techniques.  Attends and constructively participates in team meetings as scheduled.

• May suggest, collaborate and implement/improve on effective work methods, machinery, documentation, materials, safety and team projects that could improve products, people, profits and lower cost and scrap.  Assist in monitoring production quality.  May assist in the entry level training and acclimatization of new employees.

Safety and Security:

Observes safety and security procedures; Reports potentially unsafe conditions; Uses equipment and materials properly at all times; Works in a manner that promotes prevention of accidents/ injuries.

Accountability

• Quality, quantity and length of completion time will be measured by ISO/AS and department guidelines to evaluate performance, productivity and efficiency.  Correct usage of SPC will be measured by evaluating quarterly reports that depict CPK.  Tracking internal complaints, written N.R.M.s, participation in team problem solving and cooperation with co-workers and departments will also be evaluated. 
• Working knowledge of machinery will be evaluated by proficiency on each apparatus, number of orders produced in comparison to a normal output and coaching ability with new employees, if applicable. 
• Monitoring and adjusting will be measured by operation time, break downs, product and process specifications quality.  Documentation will be evaluated by accuracy and timeliness.
• Performance will be measured by trade tests, initiative, adaptability, attendance and compliance with supervisors, company, safety policies and procedures.  Monthly employee productivity efficiency reports, rating of housekeeping, effective communication with peers and percentage of scrap produced both individual and collectively will also be evaluated.

Essential Knowledge and Skills

• Able to accurately calculate decimal and fractional equivalents in the production process.  Able to use precision measuring instruments including micrometers, calipers and tensile testers, as well as fixtures and gauges to check work.
• Able to read, write and/or communicate the English language in an understandable manner with various levels of personnel.  Able to read and understand material lists, specs, inspection standards, production orders and related instructions.  Able to operate and work from detailed instructions and make minor decisions as to the quality and operation of equipment, machinery and product.
• If applicable; able to operate forklifts, safely.
• Able to identify, to make independent decisions and/or take action when circumstances warrant.   Able to work autonomously and as part of a team. Able to take responsibility for one's action which includes, conduct, attitudes, quality and quantity of work, communication, accuracy and timeliness, and the like.  Respectful of others, courteous attitude and cooperative with co-workers.  Able to deal with anger reactions and take a positive approach.
• Competent, which is defined as currently able to perform the job, experienced, intelligent, ethical and having growth potential.  Able to act decisively and quickly when necessary.

Essential Experience and Qualifications

• Requires a well-rounded knowledge of manufacturing techniques, tools and equipment, materials and plant practices normally obtained through a completion of Trade School, 1 to 3 years’ experience in a manufacturing environment, or equivalent.

• Must be able to work on a variety of machines within the department.  Must have or acquire data entry skills for the company SPC computer program.
• May need to obtain certification to operate a forklift.
• Must be 18 years of age or over.  Must comply with the company's Drug, Alcohol Abuse and Firearms Policy.

Physical, Mental and/or Sensory Requirements              

(With or without the aid of mechanical devices.)

• Able to stand approximately 60% to 90% of the time running machines, on a concrete floor.
• Able to cut wire with cutters using approximately 5 pounds of downward pressure with momentum.
• Able to move small spools and reels onto/off of payoffs and take-ups weighting up to 55 pounds, requires downward force using a lever system and body weight, approximately 20 pounds of pressure, 5 to 25 times on average, per shift. 
• Able to roll large 500-pound spools off of payoffs.
• Repetitive body movements in the production of products include pulling wire through till force, approximately 5 to 10 times per shift.  Proper body mechanics and lifting techniques required.

• Visual inspection and monitoring of machines, products and the like.  Able to distinguish wire quality including smoothness, scraps, nicks, discoloration, and the like, by vision and touch.
• Eye-hand-foot coordination is essential.  High degree of hand/finger dexterity. Requires 100% concentration and alertness.

Working Conditions

• Works in a manufacturing environment (plant/office) focused on cleanliness and safety in accordance with OSHA and company standards.  Works in a climate where temperatures vary.
• May be subject to injury from scratches, bruises, punctures or burns from equipment/materials. May be subject to manufacturing chemicals.  Personal Protection Equipment is required, as needed.

May be expected to work beyond normal working hours, on weekends, holidays and on other shifts when necessary.