Master Production Mechanic

Summary:

Utilizing a proven set of skills (electrical, mechanical, hydraulic, production flow, plc and communication) Perform set up, routine maintenance, adjustments, troubleshooting and repair beyond routine maintenance on production line equipment including but not limited to unscrambler, filler, capper, labeler, conveyors, case sealer, box maker, bundler, case packer, palletizer and other ancillary equipment per line design, as well as pneumatic, hydraulic and electrical machines.

Review and verify the quality and quantity of products online. Keep line workers informed on daily production needs and procedures. Will be actively engaged in all production line activities including running the production equipment, facilitating break rotation and training of new operators. Coordinate and/or facilitate safety briefs and continuous improvement ideas/initiatives for the production line.

Primary Functions:

Leadership: Assist lead operator to ensure production line runs efficiently. Includes but is not limited to:

Production

• Help establish ownership for cleanliness and smooth operation of packaging line.
• Help identify and resolve issues that impede production lines from achieving or exceeding stated performance targets.
• Serve in a mentorship capacity to all entry level employees. Drive and in-still proper maintenance guidelines and procedures by demonstrating them in day-to-day activities.
• Exhibit mentality that no job is too small or insignificant to not be done correctly and with a sense of urgency.
• Ability to act as Lead as required by business needs.
• Assign daily job assignments to production team as needed.
• Train operators on production line tasks and equipment operation.

Maintenance

• Anticipate and correct problems with initial start-ups, set-ups, new components, etc.
• Identify and provide solutions to issues that hinder the maintenance operation and provide a safe workplace.

Essential Functions:

Maintenance

1. Know how to set-up and adjust line for various products (change overs) within allotted time frame. Facilitate training of line operators.
2. Ensure/verify overall quality of finished goods is established after change over (torque settings, fill level, label placement, square boxes, etc.)
3. Diagnose machine malfunctions and make necessary adjustments or repairs.
4. Make necessary repairs to equipment to ensure quality of finished goods.
5. Perform routine daily maintenance as required.
6. Perform established periodic preventative maintenance.
7. Ability to plan and complete in-depth rebuild of equipment without direct supervision.
8. Ensures all required components and equipment are onsite for rebuild.
9. Able to direct others in the rebuild process to ensure timely completion.
10. Responsible for coordinating inventory of repair and change parts.
11. Conduct audits of parts inventory
12. Inform Supervisor of parts and equipment used and needed for replacement.
13. Ability to differentiate mechanical, including pneumatic and hydraulic vs. electrical malfunctions.
14. Apply knowledge of electrical principles to diagnose and resolve electrical malfunctions such as fuses, boards, drives and motors.
15. Knowledge of PLCs to include ability to interpret correctly input and output signals, how to test input and output signals and exhibit working knowledge of system design and operation of the production line.
16. Ability to read and interpret ladder logic, electrical or other technical schematics to troubleshoot and correct equipment or line malfunctions.

Production

1. Advise, instruct, and recommend suggestions in the decision-making process of adjustments of operators.
2. Key role player in the set-up for testing of new components and products.
3. Proficient in operation and repair of all automated equipment.
4. Process and store hazardous materials in accordance to established local, state and federal guidelines.
5. Maintain a clean work area; pick up debris.
6. Ensure line runs with minimal downtime.
7. Champion GMP and Safety compliance on their assigned production line.
8. Assist with directing operators on line rotation.
9. Perform production start-up, assist with monitoring of line operation and products being produced as well as overall line/worker performance.

Essential Function Skill Level:

Maintenance

• Demonstrate understanding of lock-out/tag-out procedures
• Exhibit understanding of shop safety
• Select and differentiate appropriate use of various hand tools
• Demonstrate appropriate care of hand tools
• Identify safe use of ladders, crossovers and other reach tools as applicable
• Disassemble, repair, and correctly reassemble machinery/equipment
• Test operation of newly repaired machinery/equipment
• Maintain operating condition and perform preventive maintenance of the machinery/equipment
• Analyze test results, machine error messages, and information from operators to diagnose machinery/equipment problems
• Maintain record of repairs and maintenance performed IE: Limble
• Identify appropriate applications of various gears and drives
• Apply principles of mechanics
• Ability to use scales, tape measures and calipers
• Exhibit knowledge and interpretation of electrical symbols.
• Ability to correctly use Multi-meter to troubleshoot and correct minor electrical faults including but not limited to ground faults, short circuits, faulty breakers, conductivity, amperage, etc.
• Demonstrate knowledge of basic electrical operations across all voltages used in the facility.
• Apply basic electrical principles including but not limited to:
• Apply basic electrical principles of motors
• Exhibit knowledge of use and function of VFDs
• Proficient interpretation and application of hydraulic and pneumatic principles to troubleshoot and resolve/repair malfunctions.
• Proficient interpretation and application of motor types including but not limited to linear, servo, AC induction, DC motors, transformers, air cylinders, hydraulic cylinders, etc.
• Demonstrate knowledge and interpretation of basic programmable logic controllers (PLCs).
• I/O functions, PE functions, Sequence of events, etc.
• Exhibit knowledge and interpretation of hydraulic and pneumatic symbols.
• Correctly apply knowledge of hydraulic and pneumatic components
• Working knowledge in the identification and proper use of motors (linear, servo, AC induction, DC motors and transformers)

Production

• Demonstrate knowledge of appropriate set-up procedures
• Identify and troubleshoot component defects and malfunctions
• Determine root cause & resolution
• Able to work as a team player with the rest of the production crew
• Foster an atmosphere of collaboration with the other assigned line mechanics
• Ensure proper pass down of daily events to ensure success for the oncoming shift

Education:

• High school diploma or GED
• Industrial Electrical Maintenance (preferred, not required)

Work Experience:

• 3 - 5 years maintenance mechanic role; using the latest technology and staying knowledgeable of changes in technology, including but not limited to: PLC, Motors (linear, servo, AC induction, DC motors) and Transformers.
• Demonstrated understanding of production lines and no safety violations. Ability to add, subtract, multiply, divide and simple use of formulas.
• Must be able to complete Lead Operator training program.

Physical Demands:

• CRITICAL TO THE JOB: Standing & walking – 95% of time on job; sitting 5% of time on job; lifting (minimum 30 lbs) 10% of time on job; - pushing & pulling (minimum 60 lbs) 35% of time on job; repeated rotation of the wrists - 66% of time on job; climbing stairs & ladders (8-20 ft heights) – 15 times per day; stooping, kneeling and bending - 60% of time on job; hearing; vision (fine detail – 80% of time on job; distance – 30 ft); tracking moving objects - 80% of the time on job.
• HELPFUL TO THE JOB, NOT CRITICAL: Ability to carry objects and ability to reach.