We are seeking a Process Technician to ensure the safe, efficient and continuous operation of our polyurethane foam manufacturing process. Responsible for controlling, monitoring and optimizing all aspects of the production process to meet quality, output and safety targets while minimizing waste and downtime.
- Grade 12 / N3 school leaving Certificate.
- Diploma In Chemical Engineer/ Industrial Engineering/ similar
Chemical Condition
- Ensure chemical levels, load material, check chemical conditioning and record temperature on SPC charts are being done.
- Check chemical pumping system for air and chemical leaks, check traps. Check tank pressure and stirrer.
- Maintain optimum chemical levels, assist with loading of material, verify chemical conditioning parameters
Machine Preparation and start
- Conduct tests pour in bag to check mixing.
- Check pressure to ensure mixing is optimised and no pressure drop is present.
- Check that pressure on all chemicals and additives pressure is balanced to the correct ratios.
Calibrate Pumps and Establish Flow Rates
- Calculate required flow per second dependent upon cream, rise times & part size.
- Check dosing parameters for all additives and ensure all recording and control equipment is accurate.
- Ensure formulations, rise profile, and cream times are confirmed by laboratory.
Product validation
- Support in setting pour patters and ensure proper sealing of moulds.
- Support in layouts of cutting material
- Ensure correct materials are being utilized for parts
- Timeous implantation of lean manufacturing principles
First-Off checks
- Visual checks of production to assess product conformance.
- Assist with ensuring pouring mass is within product specification and commercial parameters.
- Check and document changes to formulations, flow rates, pour times and chemical dosing ratios.
- Ensure specifications are updated for all machine requirements.
Monitoring Of On-Going Production
- Ensure production processes are maintained within specified parameters
- Maintain manufacturing and production efficiencies
- Ensure the optimal and efficient use of resources
- Monitor the achievement of daily production targets
- Analyse daily variances and identify opportunities for improvements
Fault Finding/ Trouble Shooting
- Using experience, records on the SPC charts to ensure fault finding is rapid and follows a systematic process.
- Also use established trouble shooting guides and case studies to diagnose faults and take appropriate action.
- Record all faults in case study files for future reference.
- Document all faults in case study files for future reference.
- Conduct thorough investigation in support of customer queries.
Rejects/ Repairs Analysis
- Production records must be reviewed to establish the cause of failures.
- Ensure data is readily available for fault finding (example graphs)
- Assist with completing all corrective action reports. Monitor rejects and scrap and ensure scrap and reject targets are met.
Training
- Where errors are found, re-training of production personnel is necessary. This must be carried out across all shifts.
Customer Returns
- Where customer returns occur proper fault analysis must be conducted to establish if the problem was a machine, chemical or operator error.
- Implement effective controls to prevent recurrence.
Industrialisation Of New Samples or Processes
- Ensure engineering development samples are manufactured under production controls.
- Keep individual files for each product developed which will include the B.O.M, E.P.R, relevant specifications and mass capability studies.
- Details of all problems and solutions must be recorded
Continuous Improvement/ Value Analysis- Value Engineering (VA/VE):
- Analyse existing parts and processes to optimise OEE and operating cost.
- Programming of PLC for part changes or new products.
- Ensure that quality standards are achieved and always maintained by the production teams.
- Document and Issue engineering change reports/ trial request forms.
Audits
- Support all audits internal and external
- Assist in review of control plan and FMEA
