Process Optimization Specialist

SUMMARY
The IM Manager and the IM Lead Supervisor rely on and value this Process Optimization Specialist position. The value includes but is not limited to, counseling the IM Manager, Lead Supervisor, Shift Supervisors, and Job Setters. An additional value is that the Process Optimization specialist is a hands-on opportunity, within the department, helping ensure that the injection molding department runs as efficiently as possible.

ESSENTIAL DUTIES AND RESPONSIBILITIES
Optimize IM processes, creating the most efficient and cost-effective production lines utilizing operators and/or robotics in a mold and assembly operations.

Responsible for representing the Dayton IM Department in all product launches.

Lead and complete a monthly continuous improvement project, that is preapproved by the IM Manager and the MPS Manager.

Develop and troubleshoot the manufacturing process of plastic injection molding using polypropylene and nylon resins.

Be the lead troubleshooter for all process and equipment in the IM Department.

Set up and optimize injection molding processes for new tooling, including molding machine parameters, peripheral equipment, and robot programming.

Maintain Molding Conditions for injection molding, revising as needed.

Troubleshoot processing problems related to quality issues.

Improve molding process to reduce cycle times to a determined level per IM Manager.

Lead the projects of Cycle Time and Scrap Reductions, setting up weekly meetings where you lead a small team within IM that should include Quality, Maintenance and MPS Team members.

Communicate and spend time across all 3 shifts on these projects, getting ideas of new projects as well as working on the projects with all shifts and then teach all the shifts the changes the department wants to make and the new process, the team has agreed to, to be implemented.

Include IMs MPS representative on every move made on this project.
Document every process by Mold #, tracking each attempt.
Expectation is to track a true Cost Savings to every mold / process IM runs.
IMs MPS support will be the Official / Guarantee that the report out to the Lead Team and Corporate is 100% accurate on the Cost Savings.
Report out improvements, issues, and next steps to be made in Cycle Time Reductions as well as Scrap Reductions at the Weekly Staff Meeting.
After being verified by Daytons MPS Team, you will present these Cost Savings at the Weekly / Tuesday Profit & Performance Meetings.

Work with Production Team / Job Setters to meet Goal / Expectations by Quarter, until overall Goal is met by the end of Q4, 2024 and is sustained for 6 straight months.

Collaborate with Tooling Engineers, Quality Engineers, and Tool Maker Lead on tooling issues, when they are found, in the moment. (Mold, EOAT and Subassemblies and Auxiliary Equipment are all included under tooling.)

Lead Weekly Mold Flash Repair & Mold PM Meetings.

Goal is no parts trimmed by hand.
Goal is for molds to have PMs completed in a timely fashion and never go 5% past shot count.
Goal is to complete 100% of the Annual PMs within 30-days of being due.
Service molds need special attention preparing them for production and then preparing them for safe storage until next use.

Interact positively with department leaders, production supervisor for scheduling and troubleshooting requirements.

Help guarantee production schedule is met weekly, helping prepare for mold changes and removing obstacles in advance that may hinder making the production schedule be 100% accurate.
Ensure Mold Books are updated weekly.
Ensure Mold Books are safely inventoried and stored weekly.
Ensure Dayton IM has updated Mold Books and EOAT for 100% of Dayton Service Molds, inventoried monthly.
Ensure required work is completed for production to have bar codes accessible before each production run, tied to proper Packaging Instructions.

Train Job Setter Technicians, to improve operational efficiency on Injection Molding machines.

Teach / train Dayton Certified Job Setters, twice a year on the new technology advancements that have been made in the IM Department, guaranteeing their skill level in these new technologies exceeds Mahle Dayton IM expectations.
Setup individual Training Packages for each trainee Job Setter in training, detailing out the specifics on:

Goal is for a trainee Job Setter to become a Certified Job Setter in 18-months.
Items and areas and dates that you will be teaching the trainee Job Setter.
Items and areas, dates and who will be teaching the trainee Job Setter to get the best inhouse training experience possible.
Arrange for outside training with press suppliers, automation/robotic suppliers and auxiliary equipment suppliers that could expedite the training experience for the trainee Job Setters.
Keep weekly documentation for 100% of the trainee Job Setters, testing them at the appropriate time with tests you may have to make if tests cannot be found outside the Dayton IM Department. Adjusting the training system to benefit the trainee in hoes to guarantee their success.

Establish a Scrap SOP for tracking daily.

Write equipment specifications, performance requirements, cost analysis, and proposals for integrating injection molding machinery and equipment.

Confer with management, engineering, and other staff to determine manufacturing and injection molding processes.

Work overtime as needed/deemed by IM Department Manager, IM Lead Supervisor or the Plant Manager for 2nd and 3rd shifts.

Expectation is, at a minimum, you are on call by phone when the IM Department is in production, 24/7 including weekends and holidays.
Expectation is; if the situation cannot be resolved by phone that you travel to the plant and support the team and resolve the issue.

Lead material change requests including the addition of regrind into the current process.

Organize and run trials with support from Production and MPS and outside engineers.
Ensure proper testing and samples are completed the first attempt ensuring, or doing your best to prevent the need that future trials will not be necessary, doubling the workload.
If trial parts are approved by Mahle Engineering and Mahle customers, the expectation is to move forward with all the outside resources, with the Dayton MPS Team alongside tracking Cost Savings and implement a successful project.

Work Hours
Normal workday is 7:00AM to 5:00PM.
On call whenever IM is in production parts.
If called, and the call is not answered, expectation is that you call the IM Supervisor within 30-minutes.
If the phone call does not resolve the issue, you are expected to commute to the plant within 30-minutes to support and resolve the issue.
Expected work week consists of 50-plus hours, unless approved by the IM Department Manager.

QUALIFICATIONS
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or training; or equivalent combination of education and experience.

LANGUAGE SKILLS
Ability to read, analyze, and interpret common scientific and technical journals, engineering drawings, financial reports, and legal documents. Ability to respond to common inquiries or complaints. Ability to prepare documentation that conforms to prescribed style and format. Ability to effectively present information to management, customers, and/or internal work force.
PHYSICAL DEMANDS
The physical demands described here are representative of those that must be met by an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this job, the employee is frequently required to walk, stand, or sit.

Do you have any questions?
JADA.FOY@MAHLE.COM

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