Qualified candidates will possess the following Minimum Requirements:
•High school diploma or GED
•Completion of an Associate’s Degree in Tooling & Manufacturing (or similar program) or completion of a college-based or apprenticeship-based Tool & Die or Technician program or certificate
•Ability to train, teach, and assess other Die Technician trainees in the Career Path program, working well and leading and mentoring in a team environment
•Experience in the prototype or tool & die trade, specifically making, repairing, setting up, trouble-shooting and running dies
•Proven ability to work with progressive, transfer, compound, hand-feed or feinblank dies.
•Skilled in machine shop and machining operations, including welding
•Proven ability to assist with managing projects and resources effectively, including detailed documentation on tooling issues and component prints
•Excellent problem-solving and trouble-shooting skills
•Ability to pass written and practical tests to obtain company hi-lo and crane license
•Proven mechanical inclination, general math and manufacturing knowledge, and trouble-shooting skills through standardized assessments
•Ability to lift 50 pounds
•Must not wear tinted safety glasses, or have a need for tinted safety glasses
•An excellent work record, including attendance
•Complete necessary paperwork for die books, tool biographies, (and EAM, if applicable), and complete and ensure stock replenishments.
•Optimize and communicate knowledge base (including documenting die build and tool tryout issues, and ensuring CAD data and die books are updated) to enhance future die designs.
•Maintain proper inventory in, and organization of, the die sensor tool chest.
•Maintain inventory and organization of all die detail components and sensors within defined inventory locations; receive, relocate, and issue components from defined inventory locations.
•Document hours and work activity daily in record-keeping system—Electronic Asset Management (EAM)—using proper repair codes.
•Prioritize and organize die repairs, work orders, components, tracking, parts, and tooling information in data systems (Kanban, EAM, Jasper). Complete and submit Maintenance/Repair/Operations (MROs) to set up stock replenishments in EAM.
•Create die changeover instructions, die repairs, and end of run issues, ensuring CAD data and die books are updated, and Managers are notified of any issues. Ensure all instructions and documentation are saved electronically in the correct location.
•Use stock lists generated by the die design team to ensure all die components are present, and if they are not, notify Manager or a lead Die Technician.
•Visually compare die components with CAD data to ensure accuracy, including heat treating process (if necessary). Notify Manager or lead Die Technician of any heat treating and altering of any inaccurate die components.
•Drill, set, and attach the necessary parallels.
•Assemble, set, and dowel necessary die component details, drilling and mounting the blocks in the proper locations, ensuring trim steels, punches, and embosses are properly placed and meet tolerances.
•Assemble all remaining die component details from stock lists and notify Manager or lead Die Technician to verify that the timing is correct.
•Load dies with die springs and nitrogen cylinders.
•Perform die tryouts, including setting dies, clamping die bolsters, loading coils, and feeding coil stock. Ensure dies are built accurately (t-slots, cone locators), and shut heights and feed heights are correct. Create smart pac cams for feed rate, sprayer timing, sensor timing, shut height, and overloads. Alter servo transfer systems to set fingers or fine blanking presses, as needed. Notify a lead Die Technician of any component changes, including such items as ejector pins, screws, dowels, and stripper pads.
•Operate a variety of machine tools to spot, grind, and finish hardened mill blocks to verify specific dimensions, as well as build, assemble, install and adjust fingers in presses per design or instruction.
•Perform the duties needed to prepare to install sensors into dies and fingers, such as verify replacement is needed, retrieving and reviewing designs and diagrams to determine optimal placement and accessibility, and organizing and labeling wires, ensuring proper channels lead to sensors.
•Identify, select, install and replace sensors, guarding and valves based on function, application, and information from diagrams. Ensure that sensors, wires, boxes on rails, valves, cylinders, and hoses are protected. Document items needed for installation, including sensor and pin location and work performed, via pictures, EAM and sensor installation sheets.
•Wire, verify, and adjust sensors, valves, and cams (using tools such as SmartPac and sensor cart) for proper clearances and timing to ensure optimal performance (including die clearance and timing).
•Install, plumb, and secure sprayers and sprayer components in dies properly, as well as chutes, keeping clear of all moving parts (fingers, pads, incoming material, etc.).
•Work with press technicians and process engineers to verify that newly built dies are built accurately (t-slots, cone locators, trim steels, punches, and embosses are properly placed and meet tolerances), that shut heights and feed heights are correct, and that the dies are timed out properly. Notify designer of any component changes, including such items as ejector pins, screws, dowels, and stripper pads.
•Perform the tasks needed to repair dies, including clean components, change out cracked or damaged tooling, sharpen and shim, weld, grind, cut hardened components, inspect and sharpen trims, punch, and die steels, polish forms, prep backup and changeover tooling before it goes to the crib, and check parts on the fixture, and spot the detail back into a part or model of what the block shape should be.
•As necessary, program transfer systems to optimally transfer parts from station to station.
•Build, assemble, install and adjust fingers on die horses and in presses.
•Build and repair fabricated components using the MIG welder.
•Troubleshoot automatic and hand-feed tooling and set-ups in-press.
•Use data (EAM, operator observation, visual inspection, measurement, etc.) to problem solve needed die changes.
•Use Smartpac and press controls modifications to ensure presses operate optimally.
•Validate process parameters and notify the proper operations group to enter system deviations when applicable.
•Alter or adjust die components to ensure die operations the produces optimal parts.
•Combine problem solving methods with data (EAM if applicable), information from technicians/operators, information from part strip, elongated pilot holes, mismatched cuts, and burrs) to determine the specific changes needed for each die.
Continuous Improvement/Lean Principles:
•Apply continuous improvement concepts to dies and the changeover process via preventive maintenance and corrective actions, making adjustments to better the quality of the part and life of the tool, cost savings, fixing overlooked areas (such as stone the die sets, clean the dies, remake worn steels and die components), simplify the dies, and identify potential cost savings for pitch and width reductions, and ensure back up tooling is correct and present.
•Identify and attempt to eliminate areas of waste for better efficiency and overall production needs.
•Anticipate die and operation problems and work to eliminate them before they happen.
•Participate in, and support lean initiatives such as continuous improvement events and problem solving events, identifying and eliminating all types of waste
•Suggest and implement ideas to increase personal and departmental efficiency. Communicate potential cost savings to other Technicians and Manager.
•Participate in 8D and 5-Why problem solving teams, Plan-Do-Check-Act (PDCA) events, die improvement reviews, and die reviews.
•Make the necessary sample parts and submit them to the metrology lab for layout.
•Use and maintain quality tools such as calipers, micrometers, height gages, solid squares, pin gages, dial indicators, Joe blocks, 1-2-3 blocks, machine parallels, angle plates, sine plates, V-blocks, precision vices, protractors, feeler gages, radius gages, and telescoping gages.
•Verify tooling components for accuracy before use, including using the layout on tooling detail prints to verify tooling accuracy. Verify that parts produced are manufactured according to requirements; document as needed per control plan.
•Examine forms for thinning and hard mark areas, implementing tooling changes as needed.
•Use available quality data (Statistical Process Control, Coordinate Measuring Machine checks, control plans, visual inspections) to verify that parts meet quality standards.
•Consistently adhere to, and support, company policies and procedures, including ISO, TS 16949 and safety regulations.
•Safely use hi-lo and cranes, maintaining licenses, maintenance schedules, and inspection sheets. Use overhead crane to dry run dies, checking for interference between upper and lower die shoes. If interference is found, notify a Die Tech I of the inaccuracy immediately so the interference can be adjusted accordingly.
•Follow all safety procedures, including Personal Protective Equipment (PPE), controls, safety devices, lock-out/tag-out, use of coolants, and die block procedures. Identify potential safety issues and take appropriate action. Ensure environment is free of avoidable risks, and report concerns immediately, taking appropriate action to immediately rectify and resolve.
•Organize and maintain personal work area and tool room per 5S standards. Notify Team Leader if repair or replacement of machinery or equipment is needed.
•Effectively communicate with co-workers and management personnel to enhance teamwork and communication initiatives. Provide necessary, accurate, and timely feedback of all pertinent information to co-workers and management, including training and validating/appraising work of other Die Technicians at lower levels.
•Train new and existing employees on all aspects of Tool & Die build and repair, using Training Checklists as a guideline. Mentor new and existing employees in areas of needed skill development as appropriate to job duties and requirements.
•Know tooling and capability run dates, and communicate any information that would prevent those dates from being met.
•Consistently exhibit appropriate attendance habits, working the hours necessary to perform the job, and being at the work station on time at beginning of shift and after breaks, working until end of shift.
•Accept instructions and duties in a positive manner, while treating all co-workers with dignity and respect. Seek clarification for complete understanding, and process information for job independence and elimination of waste.
•Assist in maintaining company values (Integrity, People, Customers, Ownership, We Can If….Safety) daily, through thoughts and actions.