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Sr. Foreman

SUMMARY
The Sr. Foreman is responsible for assisting the shift supervisor with regards to shift production employees and production equipment in the Co Extrusion. Assists in overseeing the training, upgrading, evaluation and performance reviews of shift personnel. Assists in performing administrative duties as required including, initiating personnel action forms, writing counseling forms, vacation requests and any other reports as needed. Maintains adherence to company policy and procedures. Helps to maintain the shift safety program to minimize accidents and injuries and to ensure a safe working environment. Must know Co Extrusion lamination grade material blown film, troubleshooting, extruder drives, heaters and controls. Constantly follows quality and production and makes the necessary decisions to maintain maximum rates with high quality in an efficient time and manner. Assists in coordination with Maintenance for scheduled shutdowns and repairs in order to achieve the necessary maintenance work with the minimum operational losses. Inspects each line and checks the product is being run according to the specifications of the job; takes corrective action to resolve problems. Closes out production work orders and records production on a daily report. Forecast equipment for future orders.
ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned.
I. MANUFACTURING;
Assists Shift Supervisor in all of the following: Prepares jobs for production. Verifies that all the information is included and accurate so it complies with the work order. Assigns personnel to production lines. Must meet production, quality and quantity standards on all lines. Assures proper set-ups and quality checks. Organizes work for smooth operations. Constantly follows quality and production and makes the necessary decisions to maintain maximum rates with high quality in an efficient time and manner. Assists in training staff on how to do quality checks, check gauge, length, width and weight and does follow-up on production to ensure product is being produced to specifications and documents paperwork. Helps staff make necessary adjustments and settings to equipment and oversees the set-up of all trouble orders. Can operate all aspects involved in a start-up, process control blending system, recalibration and control panel, printing press and bag separator and can take a line down properly. Must be able to troubleshoot the majority of problems on extrusion, towers and winders. Helps to implement training programs for staff to learn the components of extrusion, and how these components work together to make quality film. Must know resin system and the various resins used for their application and in what capacity. Inspects the finished products for quality problems and takes corrective action to resolve problems. Notifies Shift Supervisor of equipment and maintenance problems; advises of quality problems. Collects data during the shift regarding line speeds, output rates, and downtime. Replaces broken or worn out hand held equipment. Insures safety requirements are being met and that all employees have their PPE available and are using it correctly. Must be willing to work twelve-hour shifts and additional hours which may be additionally compensated with management's authorization.. Establish and maintain housekeeping standard that meet or exceeds the overall plant standards. Analyze employee skills in cross training programs and arrange training as required. Test skill levels on a regular basis. Recommend pay increases or promotions based on employees work performance and progress in gaining job knowledge. Conducts performance appraisals. Counsels employees as needed in regards to work performance, attendance, safety or other issues. Conducts monthly meetings to keep employees informed on production goals, company policies/rules and safety. Informs shift personnel of goals and where they stand toward meeting the goals. Attends other meetings as required by Management. Make recommendations or suggestions to improve processes and procedures. Shuts down lines for repair or hazardous conditions.
II. OPERATIONAL COMMUNICATIONS;
Reads work orders and check production reports on the lines. Verbally communicates with all Shift employees, Production Manager, Management Staff and Maintenance.
III. HEALTH AND SAFETY;
Adheres to safety policies and procedures in compliance with AEP's guidelines. Visually inspects production area for tripping hazards, equipment safeguards, employee's safety, adherence to policies and maintains compliance with OSHA and housekeeping rules.
QUALIFICATIONS
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required.
EDUCATION and/or EXPERIENCE
High school diploma or equivalent or several years of blown film manufacturing experience. Good written and verbal communications skills are required as well as computer skills and mechanical background.
LANGUAGE SKILLS
Ability to read, write, understand and communicate in English. Accurate data entry will also be required for completion of various reports.
MATHEMATICAL SKILLS
Ability to do functional math; i.e. adding, subtracting, multiplying and division. Ability to use a handheld calculator to figure percentage formulas and out-put yield. Must be able to confirm calculation of the density of the blend and percentage of layer thickness with micrometers. Accurately read a tape measure.
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 the job.
While performing the duties of this job, the employee is regularly required to talk and hear. The employee must be able to keep up with moderate to high speed production machines winders, extruders, blenders and pumps. Manual dexterity required with exposure to arm, wrist and back fatigue on occasion. The employee uses their arms, hands and fingers to handle, grasp, hold, grip, push, pull and squeeze. The employee may be required at times to bend and lift up to 65 pounds. Occasionally, the employee kneels, squats, pulls and drags sheets of plastic, rearranges and organizes products/materials, climbs/descends stairs into/from the tower areas 50 to 65 feet in the air. The employee stands and routinely walks the production area to check production, consult with employees and offer assistance where needed. Knowledge in the usage of pallet jacks, roll carts and forklifts are required.
WORK ENVIRONMENT
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions on this job. While performing the duties of this job, the employee is constantly exposed to moving mechanical parts. The noise level in the work environment is usually moderate to very loud. Hearing protection is provided and required in designated areas of the plant. An essential part of this position is to work in a teamwork environment. The employee is continuously exposed to temperature variances; heat during the Summer and cooler temperatures during the Winter.



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