Setup Technician Team Lead

Uses advanced technical knowledge to troubleshoot, adjust, set up, and support plant production equipment. Performs all duties associated with the setup of die casting equipment to produce quality products safely and efficiently.

In addition to technical responsibilities, serves as the Shift Leader
, providing day-to-day leadership and coordination of employees assigned to the shift. Ensures production priorities, safety requirements, quality standards, and company procedures are followed throughout the shift. Acts as the primary point of communication between shift employees, supervisors, maintenance, quality, and other supporting departments.

Job Responsibilities

• Perform die cast mold changes and cell adjustments according to the production schedule, following SMED procedures, including die setup, die connections, and correct process parameter settings to achieve and maintain production targets.
• Ensure die changes are started on time based on the production schedule and established changeover priorities.
• Verify and make corrective adjustments to dies and peripheral equipment, including hose changes, limit switch cables, cylinder changes, plunger rod changes, plunger and shot tip changes, and emergency die changes due to damage to ensure proper and continuous operation of the Die Casting Machine.
• Verify that all tools, equipment, materials, and other items required for setup are available and ready for use prior to beginning the setup.
• Move casting and trimming tools to the appropriate casting cell where the setup will be performed.
• Move all additional items required for setup to the appropriate casting cell prior to the start of the setup.
• Supervise and document all setup activities using the required setup checklist.
• Perform preventive actions and adjustments to reduce equipment downtime, scrap, quality defects, and production interruptions.
• Set process parameters for each product following every die change. Start the Die Casting Machine and verify that process parameters are correct according to the applicable part number, work instructions, and process specifications.
• Verify proper operation of equipment and tooling during startup and ensure parts meet established quality requirements.
• At the completion of setup, proceed with production startup and provide parts to the Quality Department for required inspection and approval, including X-ray approval when applicable.
• When no setup or die change is required, assist with keeping Die Casting Machines running production and addressing technical issues that may affect production.
• Provide day-to-day leadership, direction, and work coordination for employees assigned to the shift.
• Assign employees to machines, workstations, and production activities based on the production schedule, staffing levels, employee qualifications, and operational needs.
• Communicate shift production goals, priorities, die changes, quality concerns, safety issues, and other important information to employees at the beginning of and throughout the shift.
• Monitor production activities throughout the shift to ensure production schedules, cycle times, output requirements, scrap targets, and quality expectations are being met.
• Coordinate die changes, machine setups, troubleshooting activities, and production priorities to minimize downtime and maintain production flow.
• Monitor machine downtime and respond promptly to production interruptions. Coordinate with Maintenance, Quality, Logistics, and Management when additional support is required.
• Ensure employees follow established work instructions, process parameters, control plans, quality standards, and production procedures.
• Verify that required production, quality, scrap, downtime, and setup documentation is completed accurately and in a timely manner.
• Monitor employee compliance with safety policies, required PPE, safe work practices, housekeeping requirements, and established plant procedures.
• Immediately address unsafe conditions or behaviors and report significant safety concerns, incidents, injuries, equipment issues, or hazards to management.
• Ensure employees are properly trained and qualified for assigned work. Identify training needs and assist with on-the-job training and development of employees.
• Provide employees with appropriate work direction, coaching, and feedback regarding safety, quality, productivity, attendance, and workplace expectations.
• Address routine employee and production issues during the shift and elevate disciplinary, attendance, performance, or…