Manufacturing Associate I - The Carlstar Group

Description

Manufacturing Associate I position is a position that can be assigned to any of the roles of the below listed jobs at the manufacturing plant. The primary function of this position is for the employee to rotate between different jobs as business needs dictates- Tread Booker, Pre-Weigh Operator, Belt Loader, Bias Cutter Operator, Apex, Spray Booth Operator, Wind-Up Operator, Chafer and Fabric Salvage Operator.

Required training will be given before being placed in a role.

Summary of Responsibility for each relief role:

Tread Booker

• The primary function of this position is to take the tread sheets (cut layers of rubber) off the conveyor belt and place them in the tread storage books.
• Report to team leader for assignments.
• Discuss tread run with operator at shift change.
• Arrive at correct job location on time.
• Take sheets of tread rubber off conveyor & place them on the leaves of the Tread Storage Book.
• Use keyboard to enter information about tread run into computer.
• Tag both ends of Tread Book with Catalog Number, Date, and Shift Number.
• Transport Tread Books completed to storage area using correct equipment.
• Use keyboard to enter information about the location of stored Tread Books.
• Perform conveyor maintenance; cleans area; changes filters; changes cutters; cleans rollers.
• Exerting in excess of 70 lbs. of force occasionally, and/or in excess of 50 lbs. frequently, and/or in excess of 30 lbs. of force constantly to move objects.

Pre Weigh Operator

• The major function of this position is to provide all Chemicals from the Pre-Weigh room to be ready for the Mixer Area’s.
• Daily, take inventory estimates of the pre weighted chemicals available at the Mixer and plan the days pre weighing schedule.
• Transport Bags / Drums of chemicals using Forklift / hand cart to the pre weighing room.
• Cut open bags and empty chemicals into respective portable storage bins.
• If chemicals are hardened in the bag, loosen material using a hand tool.
• Chemicals in drums are to be pre weighed directly from drum.
• Pre weigh Compund materials are per the weight specification and tolerances, into plastic bags.
• Number the plastic bags as per pre weigh chemical listing.
• Place pre weighed chemical bags into racks / palletized boxes and move to designated storage locations.
• Clean all spilled chemicals from Scales, tables, and floor.
• Ensure the scale reads accurately (zero prior to weighing) and report any errors to supervisor.
• Inform supply department when material stocks are low.
• Maintain documents required by ISO 9000.
• Keep work area clean and orderly.
• Exerting in excess of 70 lbs. of force occasionally and/or up to 50 lbs. of force frequently and/or up to 30 lbs. of force constantly to move objects.

Belt Loader

• The primary function of this position is to load chemicals, rubber, and other ingredients that will be mixed into rubber stock used to make tires.
• Report to team leader for assignments.
• Prepares blocks of rubber by cutting in guillotine cutter.
• Places ingredients (prepackaged chemicals) on belt one at a time.
• Checks weights on computer screen - computer checks each ingredients weight.
• Occasionally will climb ladder to lead chemical hoppers.
• May be expected to oversee movement of ingredients into mixing mill.
• May be expected to enter information into MRP system.
• May assist in quality checks.
• Exerting in excess of 50 lbs. to 69 lbs. of force occasionally, and/or up to 30 lbs. of force frequently and/or up to 25 lbs. of force constantly to move objects.

Bias Cutter Operator

• The primary function of this position is to cut fabric material to desired width and cut angle.  Fabric material to be placed in storage liners.
• Report to team leader for assignments.
• Will check for right width, cut angle, and Code of fabric going into the roll.
• Will check specifications in the computer and record on cards the information and initial.
• Will stand at station and splice the fabric together.  Fabric is cut according to specifications for the desired catalog number.
• When roll is completed (cut), will take off and put on fabric rack.  Will use hoist to move to racks.
• Will pull new fabric on conveyor belt and begin splicing.
• Will splice rubber coming into basin of machine (one person slices, the other loads and services).
• Will clean up area at the end of shift.
• Will Repair and/or Re-roll Liners as needed.
• Exerting in excess of 70 lbs. of force occasionally, and/or in excess of 50 lbs. of force frequently and/or in excess of 30 lbs. of force constantly to move objects

Apex

• Primary function of this job is to Slit the Bias Cutter Fabric to the specified widths and wind Chaffer onto Spools.
• Report to team leader for assignments.
• Check schedule from computer and plan size of chaffer to be cut, Load Bias Cutter Fabric rolls onto the Chaffer Slitter Machine using Hoist.  Pull Fabric through rollers and adjust rotary cutters to the required width specifications.
• Start Slitting the Fabric and wind the Chaffer onto Spool Arbor.  Periodically checking the width of the Chaffer and discarding out-of Specification material.  If Cutters get jammed, untangle Chaffer to minimize Scrap.
• Unload the Arbors, remove the Slit Chaffer Rolls, properly mark size and place them onto racks.  Remove Storage Liners.  Update the Inventory.
• Wrap and Extrude Rubber around the Bead using Chaffer and crimping Chaffer.  When Specification call for, Wrap Chaffer arounf narrow beads without the extruded rubber.
• Chen Schedule from Computer and plan work to be done.  Load Chaffer Rolls onto Let-Off.  Spray Beads with Cement.  Load extruded rubber through the cement bath.  Adjust the machine to take required beads.
• Start feeding Chaffer onto the bead/extruded rubber and guide Chaffer wrap around the Bead.  Cut rubber and Chaffer so the required length and Flip the Bead.
• Stack the Flipped Beads on the Rack, properly Marking sizes, and update Inventory on Computer.
• Do minor maintenance work on machines.  Keep area Tidy and Clean.. Obtain/make materials required for work.  Help Operators on other Machines when service is required.
• Exerting from of 35 lbs. to 49 lbs. of force occasionally, and/or in excess of 20 lbs. frequently of force constantly.

Spray Booth Operator

• The major function of this position is to spray the inside and outside of a green tire providing lubrication between tire and mold.  Make sure all Green Tires are Coordinated from Tire Assembly to Curing Department
• Will provide proper set up procedures (check amount of spray needed for the day).
• Adjust the spray guns for proper spray coverage.
• Adjust air pressure and type of spray.
• Will take racks of green tires and check specifications for tires on each rack.
• Check tire of obvious possible cured tire defects.
• Identify the sprayed tire rack with catalogue number, date/time, and initial tag.
• Activate spray by foot peddle, when finished.
• When finished, move the racks of sprayed tires to Bar-Code Label Staging Area.
• Print and Affix Bar-Code Labels to Rack and Transport to desired location.
• Will work closely with Tire assembly and Coordinate Tires from Tire Room to Curing Department.

Wind-Up Operator

• The primary function of this position is to put finished liner on a roll.
• Moves and places let - off and wind-on rolls into their correct position
• Starts or finishes rolls per procedures
• Sets let-off roll tension brake according to procedures
• Sets electric eye and bow rollers according to procedures
• Visually inspects Rubber Fabric as Calender is running. Also checks perforation operation
• Manually moves rolls on gum Calender Machines
• Exerting in excess of 70 lbs. of force occasionally, and/or in excess of 50 lbs. frequently and/or in excess of 30 lbs. of force constantly to move objects.

Chafer

• The position is responsible for the set-up and operation of machine to support production. Detects and reports machine and product problems to supervisor. Maintains the work area and equipment in a clean and orderly condition. Follows prescribed safety regulations.
• Assemble product using various types of equipment.
• Understands the components of the machine as well as which components should be used for each process.
• Inspect product to identify defects and scrap.
• Use tools safely and efficiently
• Read and understand build specifications required for operating machinary.
• Understand and maintain hour by hour boards in daily production.
• Detect and report faulty operation, defective, and/or unusual material conditions.
• Understands and follows all safety rules associated with the job/machinary such as lockout/tagout, emergency response, and PPE.
• Exerting in excess of 00 lbs. of force occasionally, and/or in excess of 00 lbs. of force frequently and/or in excess of 00 lbs. of force constantly to move objects.

Fabric Salvage Operator

• The primary function of this position is to rework all Angle and Widths that are out of Specifications ofcut ply fabric as directed by Supervisor.
• Will identify unidentified rolls of cut fabric.
• Perform housekeeping and 5’s activities as needed.
• Additionally, this person will assist the Bias Cutters in all duties, repairs, and re-roll liners when needed.
• Will Service the Bias Cutters.
• Will Cut Fabric when necessary.
• Perform other miscellaneous duties as direct by the Supervisor.
• Report to team leader for assignments.

Qualifications

Education, Experience and Skills Required:

• Minimum of 1 year in a manufacturing/distribution operation preferred
• High School diploma/GED required, or commit to obtain a GED with Carlstar sponsored GED program within 12 months of hire date
• Ability to work in a fast paced environment while meeting production and quality goals
• Ability to obtain and maintain a valid forklift or equipment license as needed/required

Ergonomic & Physical Requirements:

• Must be able to meet the Ergonomic as well as the Physical Base Score for this position.
• Stand 50 % and Walk 50 % of a normal day.
• Lift/Carry 35 lbs. to 80 lbs.
• Lift bulky objects
• Push/pull 50 lbs. to 150 lbs.  On wheeled carts.  Static push/pull 20 lbs.
• Pinch minimum 6 lbs.
• Grasp minimum 35 lbs.
• Full range of motion required:  Cervical, Shoulders, Elbow, Wrist, Fingers, Hands, Truck Twist, and Feet.
• Working Conditions:  Moderate Noise, Moving Mechanical Parts, Static Shock, Burns, Go up Heights, Odors, Dust, Protrusions, Narrow Access, good Vision and Hearing.
• Any lifting over 70 lbs. must be completed with assistance i.e. mechanical or individual.