Mold Tech

Job Summary Own safe start-up, setup/changeover, in-process control, and documentation for Tayu vertical injection-molding cells with integrated automation (Kawasaki 6-axis robots, vibratory bowl feeders and runs, camera vision system, table cutters, and washer capping stations) to produce insulator pins for handheld conducted energy devices. Deliver production on time by fine tuning automation settings and restoring machines to standard after faults. Maintain complete in-process quality and production records, conduct quality checks using calipers and microscopes, and update Net Suite software.

Start-up and Shutdown Conduct pre-start safety checks on Tayu vertical injection molding cells: guards/interlocks, estops, light curtains, hot-oil lines, rotary table, and spill/leak conditions. Execute documented start-up: home Kawasaki 6-axis robot, stabilize Temperature Control Unit (TCU) at 320°F / 160°C for 20 minutes; warm barrel heats to 698°F / 370°C for 20 minutes; turn on manifold for hot tip controllers at 395° / 202°

C. Follow Lock Out Tag Out (LOTO) and documented shutdown for press, robot, capper, and TCU.

Setup & Changeover Stage molds for MPJ 1097 and MPJ 1238 parts, End of Arm Tooling (EOAT), raw material (shells, pins, resin), inspection microscopes and caliper; confirm Matsui dryer settings and parameters. Install molds, verify clamp plate alignment and platen cleanliness; torque clamps to specification and record values. Connect TCU supply/return; leak-check; confirm temperature stability. Pull parts at machine startup or at shift change for Critical to Quality (CTQ) checks.

For part MPJ 1097, pull 16 parts representing 1 part from each cavity from each side of the mold, and for part MPJ 1238, pull 32 parts representing 2 parts from each cavity from each side of the mold. Deliver the parts to the Quality Technician.

Process Control and Optimization Control temperature/pressure/velocity windows; monitor cushion, fill time, transfer position, pack pressure, and cycle time. Maintain upper/lower control limits (UCL/LCL); document drifts beyond thresholds and execute reaction plans.

Automation (robot, feeder, vision system, table cutter, capping station) Robot: return to home, validate safe zones, update points after mold changes. Bowl feeders: tune amplitude of the vibration controllers for bowl feeders and runs; verify orientation of parts: for Part MPJ 1097 use part MMM
0161 for the shell and MMM
0162 for pin on Work Cell 1; for Part MPJ 1238, use part MMS
0402 for the shell and part MMM
0162 for the pin on Work Cell 2; for part S01908, use part MPJ 1238 for the body and MMS
0403 for the washer on Capping Stations 1 and 2. Vision System: own dataset lifecycle: image capture, model training, and periodic re-validation on Work Cells 1 and 2. Table cutter: replace pads/cutters; set cutter height using Human-Machine Interface (HMI) with tolerance of ± 0.020 millimeters (MPJ 1097 nominal is 5.69 and MPJ 1238 nominal is 4.35 millimeters). Capping Station: calibrate height sensors;

confirm cap presence and orientation.

Quality, Metrology, and Documentation Complete the appropriate Traveler for each part (PD-WI001-F01 for MPJ 1097; PD-WI001-F02 for MPJ 1238; PD-WI001-F03 for S01908). Initial and date the Traveler for each step/operation completed. Perform caliper-based height measurements every 30 minutes; record results and trigger hold for any out-of-spec finding. The tolerance for MPJ 1097 is ±0.020 millimeters and ±0.010 millimeters for MPJ 1238.

Conduct microscope visual inspections per acceptance criteria; log results on appropriate documents (either one of the three Travelers, the Visual Inspection Sheet, or the Height Check Sheet).

Operator-Level Maintenance and Troubleshooting Perform daily checks: lube levels, leaks, heater band status, TCU temperature/flow, and dryer dew point. Respond to alarms, clear jams, reseat connectors, and replace common wear parts as trained. Perform root-cause diagnosis and recovery on vertical press and capping-station automated controls. Escalate to leadership within the defined time; document fault, cause, action, and verification.

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