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JOB TITLE: DPF Operator I JOB GRADE: NE07
FLSA STATUS: Nonexempt DEPARTMENT NAME: Materials / DPF
DEPARTMENT CODE: DPFMFG REPORTS TO: Supervisor

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I. POSITION SUMMARY

A. Operates and monitors the sifting process, which ensures that the raw materials are processed to the correct particle size specifications; operates and monitors the department's weighing line processes; replenishes and maintains sufficient levels of materials in the weighing silos and in the material staging areas; and operates and monitors the bulk unloading process, which involves unloading raw materials from railcars into the bulk silos; all of which enable the safe and efficient production of completed weigh batches, which are used in the manufacturing process

II. ESSENTIAL DUTIES AND RESPONSIBILITIES (The section is not intended to be an all-inclusive list and NGK Ceramics reserves the right to include other duties as assigned):

 Sifting duties:

A. Monitors weighing silo levels to determine shift production requirements

B. Obtains raw materials from on-site warehouse after verifying material type & raw material lot number using the Lot Designation Sheet

C. Vacuums the outside of raw material bags to ensure that no debris or contaminants are
introduced into sifters or weighing silos

D. Retrieves manufacturers’ information from bags before processing; positions bag above
hopper by using hoist; unties and attaches spout of bag to hopper opening; and empties bag into hopper

E. Verifies that sifter screens are in good condition prior to processing; charges and processes material lots in accordance with company’s work instructions; and checks sifter screens’ condition after each processed lot

F. Obtains samples from processed lots for testing and lab analysis

G. Performs Cilas machine particle size test on samples from each processed lot and notifies Technical Leader or Supervisor if Cilas test results are outside of specifications

H. Inputs processed lot data and Cilas test results into the company’s information systems; and takes samples to the Material Control Lab for analysis

I. Prepares transport setup to the correct weighing silo for Technical Leader’s approval and
transportation

J. Builds, removes and replaces sifter screens and blades as required

 Weighing duties:

A. Checks outside dust collectors & replaces bags when full; and cleans weighing silo magnets when required

B. Verifies that the correct order number and the correct starting weigh batch number are
selected on the computer before starting the weighing process

C. Ensures weighing racks are clean; radio frequency identification (RFID) tags are secured; and that super sacks are properly attached to the racks

NGK CERAMICS USA, INC. JOB DESCRIPTION

Job Code: 2750 Page 2 of 5 Effective Date: 08.23.2017
 

D. Monitors the weighing line process & reports errors or discrepancies to the Technical Leader or Supervisor & checks weigh batch tickets to confirm all weigh batches are within specifications

E. Writes batch numbers on sides of super sacks & writes body name & batch numbers on the front & back of the super sacks; ties the tops of the super sacks securely; and double-stacks weighed batches onto export pallets and loads onto rack system

F. Prepares cardboard box containers (for 2000 weighing line) & places the boxes on the proper pallets; prepares weigh batch barrels for weighing by lining barrels with the appropriate bags

G. Checks weigh batch tickets to confirm that all weigh batches are within specifications; secures tops of bags with zip tie fasteners; weighs each batch on scale to reconfirm actual weights; and writes batch data on log before placing weigh batches in boxes

H. Writes enclosed batch number range on all 4 sides (e.g. 1001-1015) & also writes body name on front & back of box container; places lid on filled container & tapes securely; and stacks boxes/pallets on floor (in sequence) in prescribed areas

 Silo Filling duties:

A. Verifies body code being weighed & checks computer (AZO visual) and silo diagram levels to determine which materials need staged for filling into the silos

B. Obtains raw materials from on-site warehouse after verifying material type and raw material lot number using the Lot Designation Sheet; and vacuums the outside of the raw material bags to ensure that no debris or contaminants are introduced into the weighing silos

C. Prints bar codes for each bag of material with the correct product name, raw material lot number and weight; transports single bags on plastic pallets and stages near elevator for a co-worker to send upstairs via the elevator; and stages correct materials in front of silo filling stations

D. Opens dust collection valves at silo filling stations; and selects appropriate silo for filling on the computer display touch screen

E. Confirms that the bar code ticket and manufacturer's information on the raw material bag matches the silo to be filled; and operates hoist to lift material bag onto the silo filling station

F. Scans the bar code to unlock silo cover; removes the silo cover; unties the material bag; empties the bag into the silo; and replaces the cover

G. Selects "stop filling" on the computer display touch screen in order to update the inventory levels in the system; and completes the paperwork (silo filling worksheet) for each lot of material that is dumped into the silos

H. Works safely by wearing the proper PPE (Personal Protective Equipment) in the designated areas (e.g. respirator)

 Bulk Unload duties:

A. Performs a system check and setup in preparation for the transfer of bulk rail materials

B. Verifies all railcar numbers in the yard

C. Inspects the railcars and ensures the proper settings of valves and petcocks

D. Verifies that the raw material lot numbers for each incoming bulk rail material matches the Lot Designation Sheet

E. Prepares hoses for transfer of raw materials in accordance with work instructions

F. Confirms the correct hose connections by examining the corresponding indicator lights on the control panel

NGK CERAMICS USA, INC. JOB DESCRIPTION

Job Code: 2750 Page 3 of 5 Effective Date: 08.23.2017
 

G. Transfers the bulk rail materials to the correct bulk silos

H. Regulates blower pressure and railcar pressure while transferring bulk rail materials

I. Obtains material samples during raw material transfer

J. Performs Cilas machine particle size test on samples obtained during raw material transfer

K. Inputs sampling data into the appropriate QSI Infinity project

L. Notifies area management if particle size data falls outside of upper or lower control limits

M. Verifies that the railcars are empty and performs the proper shut-down procedures when the raw material transfer is finished

N. Adheres to "Quiet Time Zone" procedures

O. Unclogs raw material lines as needed

 Additional duties:

A. Works safely by avoiding forklifts; staying clear of forklift doors; using personnel doors when entering or exiting the buildings; and safely uses overhead hoists

B. Participates in PM (Preventive Maintenance), MMOL (Machine Maintenance Operator Leader) and G5S (Global 5S: Sort, Set in Order, Shine, Standardize, Sustain) activities as needed

C. Follows all EMS (Environmental Management System) procedures, including the disposal of waste and used materials

D. This job has no supervisory responsibilities.

III. REQUIRED COMPETENCIES

Customer Focus. Environmental Awareness and Compliance. Functional & Technical Expertise and Computer Skills. Integrity and Accountability. Organizational Awareness. Respect and Humility. Safety Orientation. Teamwork.

IV. REQUIRED AND PREFERRED QUALIFICATIONS

A. Required Education and/or Experience

1. Must be able to successfully complete all required job training.
2. High school diploma or general education degree (GED).

3. 6 month manufacturing/warehousing experience or equivalent

4. CRC Bronze or above

5. Certified Production Technician program completion (preferred)

B. Required Language Skills

1. Ability to read and interpret documents such as safety rules, operating and maintenance
instructions, and procedure manuals.

C. Required Mathematical Skills

1. Ability to add and subtract, multiply and divide in all units of measure, using whole numbers, common fractions, and decimals.

D. Required Reasoning Ability

1. Ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form.

2. Ability to deal with problems involving several concrete variables in standardized situations.

E. Preferred Qualifications

1. Basic MS Windows software skills

2. Forklift License and Pallet Jack License.

V. PHYSICAL DEMANDS (The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions and will be determined on a case by case basis):

A. While performing the duties of this Job, the employee is regularly required to stand; walk; use hands to finger, handle, or feel; reach with hands and arms; climb or balance; and talk and hear.

B. The employee is frequently required to stoop, kneel, or crouch.

C. The employee must frequently lift and /or move up to 50 pounds.

D. The employee must successfully pass scheduled testing for respirator fitting and spirometry.

VI. WORK ENVIRONMENT
A. While performing the duties of this job, the employee is regularly exposed to moving mechanical parts; is frequently exposed to airborne particles; and occasionally exposed to extreme cold; outdoor weather conditions; and vibration.

B. The noise level in the work environment is usually moderate and occasionally loud.

VII. SAFETY REQUIREMENTS/PPE

NGK CERAMICS USA, INC. JOB DESCRIPTION

Job Code: 2750 Page 5 of 5 Effective Date: 08.23.2017
 

A. Safety shoes must be worn while on NGK property.

B. Hearing protection and safety glasses are required in designated areas.

C. Respirators are required in designated areas or under prescribed work conditions.

D. Regularly scheduled testing is performed for: lung capacity (i.e. spirometry test), hearing, and respirator fit.

VIII. EMPLOYMENT DISCLAIMER

A. This job description is not to be considered a written contract. Employment with NGK is at will. This means that the employee, as well as the company, is free to terminate the employment relationship at any time and for any reason not prohibited by law. Also, this job description is not designed to be a complete listing of the tasks, duties or responsibilities that are required of the employee.