Dudley Associates Ltd
Injection Moulding Setter
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Location: Dudley Associates Ltd, Lutterworth, Leicester, LE17 4ND
Reports To: Mould Shop Supervisor
Summary:
The Injection Moulding Setter is responsible for setting up, adjusting, and optimizing injection moulding machines to ensure efficient production. This involves tool changes, process adjustments, and troubleshooting to maintain high-quality output and minimize downtime.
Key Duties:
- Make orders to spec
- Set injection moulding machine from zero to spec
- Check material, masterbatch, and inserts match job requirements
- Ensure correct use of jigs, fixtures, and auxiliary equipment
- Reporting of cycle times and scrap variances
- Prepare and maintain material feed to moulding machines and dryers
- Conduct first-off inspection and get approval before starting production
Basic Machine Maintenance/Alarms:
- Respond promptly to machine alarms and identify root cause
- Perform basic checks: oil levels, water flow, heater bands, air lines, filters
- Clean and inspect tool faces, platens, and replace minor parts such as O-rings, sensors, and hoses as needed
- Escalate persistent or critical faults to Mould Shop Supervisor
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Machine Operating:
- Run machines safely and efficiently according to standard operating procedures
- Ensure parts are produced within specification and quality standards
- Monitor cycle times and machine performance
- Report machine faults or abnormalities immediately
Troubleshooting & Sampling:
- Troubleshoot issues, optimise cycle times, and ensure stable production runs
- Identify and resolve material feed or drying problems
- Amend machine settings to correct issues without affecting cycle time
- Work with QC when issues persist or are outside tolerances
- Coordinate and manage mould sampling for new tools and process validations
- Work with Toolmakers and Setters to resolve moulding and machine-related problems
Housekeeping:
- Keeps machines free of materials and loose parts, and work cell organized
- Dispose of scrap and waste in appropriate bins
- Clean machines, hoppers, and work areas at end of shift or job
- Ensure tools and handling equipment are stored properly
- Maintain safe walkways and clear emergency exits
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Key Performance Indicators:
- Machine Variance to cycle
- Material consumption vs. costed BOM
- Customer complaints
- Housekeeping of work areas
Required Experience/Background:
- Experience: 5 years in injection moulding setup and operation.
- Education: Technical training in plastics processing is an advantage.
- Technical Knowledge: Understanding of mould setting, process adjustments, and troubleshooting.
- Problem-Solving: Ability to identify and resolve production issues efficiently.
- Attention to Detail: Ensuring precise setup and quality control.
- Safety Awareness: Strong understanding of workplace safety standards and procedures.
Preferred Qualifications:
- Experience with specific machine brands (Engel, Arburg and Sumitomo).
- Familiarity with robotic handling and automation in injection moulding.
- Knowledge of ISO 9001, or other quality management systems.
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