Metal Coated Line (MCL) - Ternium : Job Details

1. Basic Information. Position Name: Entry Operator Helper / Exit Operator Helper / Process Utility / Entry Operator / Lab. Exit Operator / Process Operator / Exit Inspector / Team Leader/ Floater. Department: MCL Department2. Main Objectives & TasksObjectivesTasksGeneralFollow practices and procedures established for their job.Responsible to properly operate and maintain equipment and tools at their position.Responsible for complying with the safety standards of his department and the use of personal protective equipment according to PTC's or required by area.To maintain the order and cleanliness of their working area or station.Works under the Quality Management System.Participates in training programs, safety and technical courses at the times set by the company.Responsible for complying with the provisions of the Contract and Working Rules.SpecificEntry Operator HelperResponsible to un-package all CRFH staged for production to maintain production continuity.Responsible to visually inspect incoming feed coils are on a suitable condition to be processed at production line.Responsible to verify proper coil ID are being fed into payoff reels and process line based on production schedule and specifications.Responsible to feed coils into payoff reels according to production schedule and entry coil loading and preparation procedure. Responsible to perform the coil preparation and collect the corresponding sample to perform the dimensional inspection of thickness, width and flatness.Assure the instrumentation being used to perform the product inspection has its proper identification tag and calibration date is not expired.Responsible to follow inspection criteria based on entry coil inspection procedure to pulled off (reject) a coil if does not meet specifications..Fill up the production logs reports for the entry coil inspection on the frequency defined at procedure.Control and assure scrap generation is minimized to improve CTT performance.Monitor their work stations and assure their equipment is functioning properly at optimum conditions, if not, report it immediately to maintenance. Participate actively identifying unsafe conditions and report it immediately to his supervisor or head of sector.Participates in training programs, safety & technical courses at the times set by the company. Inspect coils for width and sidewall damage in coil staging areaWrite on the outside wrap of any coil rejected the reason for the rejection.Dump scrap bin twice a shift.Cut and prepare bands for pup coilsAssist in other tasks outside their area during down time.Tasks listed above are primary function. Operators are not limited to these functions and may need to perform additional tasks as required.SpecificExit Operator HelperTo review and verify production schedule to clearly identity customer requirements and specifications for process order.Responsible to perform the visual inspection of the product in order to assure results are within specification defined at general inspection procedure.Responsible to assure coils are cut out according to the weight specified at process order on the production schedule.Responsible to ensure coil winding condition and edge quality are within specifications or criteria define at inspection procedure.Responsible to set up, adjust, operate and control electrostatic oiler..Monitor their work stations and assure their equipment is functioning properly at optimum conditions, if not, report it immediately to maintenance. Participate in start-up activities with the process team in order to set up equipment and condition line. Some of the activities are: dropping pot gear, install air knives, changing rolls, threading line, etc.Participate actively identifying unsafe conditions and report it immediately to his supervisor or head of sector.Participates in training programs, safety & technical courses at the times set by the company.Perform coating adhesion testsPlace shoulder pads and tags on coilsWrite necessary information on outside wrap of coil Ensure scrap chute is clear of scrap materialDump scrap bins as needed with assistance from Lab operator.Assist with OD Bander operationsDump Retain BinsTasks listed above are primary function. Operators are not limited to these functions and may need to perform additional tasks as required.SpecificProcess UtilityPerform furnace threading activities and strip stitching after a strip break or furnace service or repair.Perform furnace cleaning activities to maintain equipment, area or work stations organization.Responsible to coordinate all sections to help on the activities to drop pot gear and install air knives during start-ups or shut-downs.Responsible to assist with work rolls, back-up rolls or cassettes change on the skin pass mill and tension leveler.Adjust, monitor and control the vertical coaters and chemical daily tanks operations in order to assure corrosion resistant products applied according to production schedule are applied within film specifications defined at fabrication criteria.Responsible to perform coater A or B roll change based on production schedule and following all the safety aspects.Responsible to condition and clean turn rolls and bridle rolls on the process section in order to eliminate dents during line operation or start-up process. Responsible to unload alloy trucks and properly store ingots into zinc warehouse according to operation procedure.Responsible to feed alloys into coating pots and make the proper consumptions into SAP according to practices.Fill up production logs or reports of their responsibility defined at the quality system.Participate actively during maintenance REX's to service and repair equipment designated by the head of sector and/or supervisor.Responsible to coordinate effective team communication between all sections (entry, process and exit) in order to assure line continuity.Monitor their work stations and assure their equipment is functioning properly at optimum conditions, if not, report it immediately to maintenance. Participate actively identifying unsafe conditions and report it immediately to his Participates in training programs, safety & technical courses at the times set by the company. Responsible to adjust induction oven as neededResponsible to fill and drain day tanks as neededResponsible to take empty chemical totes to waste waterResponsible to label waste drums and take to 90day storage when full.Responsible to take coater rolls to and from the roll grinder.Responsible to dump trash on night shiftTasks listed above are primary function. Operators are not limited to these functions and may need to perform additional tasks as required.SpecificEntry OperatorResponsible to assist un-packaging CRFH to ensure production continuity is maintained.Responsible to visually inspect incoming feed coils are on a suitable condition to be processed at production line.Responsible to enter the correct coil information into HMI's prior coils are send to the welder and process line.Responsible to maintain process line continuity by performing the coil welding process according to standard procedure.To operate, control and maintain cleaner section to assure strip cleanliness prior the annealing and galvanizing process.Responsible to maintain cleaner section variables within process specification parameters defined at standard procedure.Responsible to perform cleaner section titration for alkali, brush and rinse tanks to evaluate tank concentrations.Fill up the production logs reports for the cleaner section on the frequency defined at procedure.Enter information correctly into MES (Manufacturing Execution System) according to entry coil disposition procedure to assure head scrap cuts and pup coils are properly recorded and transfer to SAP to maintain mass balance accurate.Control and assure scrap generation is minimized to improve CTT performance.Assure coils pulled off the production line are properly identified and reason of the rejection or defects are captured (Held) in MES (Manufacturing Execution System).Monitor their work stations and assure their equipment is functioning properly at optimum conditions, if not, report it immediately to maintenance. Participate actively identifying unsafe conditions and report it immediately to his supervisor or head of sector.Participates in training programs, safety & technical courses at the times set by the company.Send out problem notifications to specified persons.Assure welding wheels are changed at intervals designated in DPP.Assure carbon stainless carbon inventories are at specified levels.Assist in other areas during down time.Fill out SGL downtime log for all entry related down time.Tasks listed above are primary function. Operators are not limited to these functions and may need to perform additional tasks as required.SpecificLab Exit OperatorTo review and verify production schedule to clearly identity customer requirements and specifications for process order.Responsible to perform the visual inspection of the product in order to assure results are within specification defined at general inspection procedure.Responsible to perform the end product quality testing for: mechanical properties, coating weights and pre-treatment film weights according to established practices on the quality system.Responsible to input production information and inspection results into MES (Manufacturing Execution System). Responsible to fill up to record production information and inspection results in the proper logs or formats defined on the quality system..Assure the instrumentation being used to perform the product inspection has its proper identification tag and calibration date is not expired.Monitor their work stations and assure their equipment is functioning properly at optimum conditions, if not, report it immediately to maintenance. Participate in start-up activities with the process team in order to set up equipment and condition line. Some of the activities are: dropping pot gear, install air knives, changing rolls, threading line, etc.Participate actively identifying unsafe conditions and report it immediately to his supervisor or head of sector.Participates in training programs, safety & technical courses at the times set by the company.Calibrate all lab testing equipment at start of shift.Collect pot samples and test them as requiredAssist with dumping scrap bins as neededScrape chill rolls and others as needed Tasks listed above are primary function. Operators are not limited to these functions and may need to perform additional tasks as required.SpecificProcess OperatorMonitor, control and optimize the overall line process conditions in order to ensure end product meets the customer specifications and/or process order scheduled.Monitor and control the process line speed and furnace annealing temperatures in order to achieve the mechanical properties of the grade requested by process order scheduled.Assure line speed standards are achieved in order to meet efficiency targets and improve productivity output.Monitors and control furnace atmosphere maintaining the proper %hydrogen to assure strip cleanliness and oxidation.Performs and monitors furnace dew points and oxygen contents to detect any possible leak that might affect furnace atmosphere and coating quality. Monitors process cooling tower to assure proper water flow rates is flowing to furnace equipment (rolls, pyrometers, jet coolers, etc.). Controls strip temperature prior entering the galvanizing baths to assure strip coating quality according to specified at procedure.Follows furnace operation and control procedure in order to start-up, operate and shut-down furnace considering all the safety aspects due to the use of hydrogen.Perform furnace threading activities and strip stitching after a strip break or furnace service or repair.Perform furnace cleaning activities to maintain equipment, area or work stations organization.Responsible to coordinate all sections to help on the activities to drop/remove pot gear and install/remove air knives during start-ups or shut-downs.Clean and inspect Air Knives prior to installation.Adjust, monitor and control air knife operation in order to meet coating weight specifications according to air knives operation and control procedure.Responsible to perform air knives homing (or calibration) process to ensure proper position reference feedback from HMI.Responsible to monitor, control and minimize overcoating in order to assure performance indicators established by area are achieved.Responsible to monitor and control quench water temperature and up-leg cooling fans according to operation standard procedures.Adjust, monitor and control tension leveler operation according to operation standard procedure in order to assure end product flatness meets customer and internal specifications.Responsible to unload alloy trucks and properly store ingots into zinc warehouse according to operation procedure.Responsible to feed alloys into coating pots and make the proper consumptions into SAP according to practices.Fill up production logs or reports of their responsibility defined at the quality system.Participate actively during maintenance REX's to service and repair equipment designated by the head of sector and/or supervisor.Responsible to coordinate effective team communication between all sections (entry, process and exit) in order to assure line continuity.Monitor their work stations and assure their equipment is functioning properly at optimum conditions, if not, report it immediately to maintenance. Participate actively identifying unsafe conditions and report it immediately to his supervisor or head of sector.Participates in training programs, safety & technical courses at the times set by the company. Address all alarms on the DAK, Line, Furnace, and Coating Weight Gauge HMIs.Start up and shut down the furnace to include turning on or off all gas valves and breakers associated with the furnace as needed.Lighting and shutting down the launder as neededConfirming that exit lab test results are within specifications.Checking all Line, DAK, Furnace, and Coating Weight Gauge HMI pages for abnormal process conditions.Perform Coating Weight Gauge standardizations as needed.Monitor strip quality as it exits the pot.Read, check and make notes to the production schedule at the beginning of each shift and each time new schedule is printedReset furnace breakers and Honeywell controllers as neededFill out SGL downtime log for all process related downtime.Tasks listed above are primary function. Operators are not limited to these functions and may need to perform additional tasks as required.SpecificExit InspectorTo review and verify production schedule to clearly identity customer requirements and specifications for process order.Responsible to perform the visual and dimension inspection of the product in order to assure results are within specification defined at general inspection procedure.Responsible to define end product quality status (pass or hold) during the coil disposition process according to operation practice.Responsible to input production information and inspection results into MES (Manufacturing Execution System). Responsible to fill up to record production information and inspection results in the proper logs or formats defined on the quality system.Responsible to perform exit coil disposition according to procedure.Assure the instrumentation being used to perform the product inspection has its proper identification tag and calibration date is not expired.Monitor their work stations and assure their equipment is functioning properly at optimum conditions, if not, report it immediately to maintenance. Participate in start-up activities with the process team in order to set up equipment and condition line. Some of the activities are: dropping pot gear, install air knives, changing rolls, threading line, etc.Participate actively identifying unsafe conditions and report it immediately to his supervisor or head of sector.Participates in training programs, safety & technical courses at the times set by the company.Responsible to set up, adjust, operate and control OD Bander.Assure coils are inspected for width and thickness at intervals defined on the quality system.Fill out SGL downtime log for all exit related downtime.Tasks listed above are primary function. Operators are not limited to these functions and may need to perform additional tasks as required.SpecificTeam LeaderMonitor, control and optimize the overall line process conditions in order to ensure end product meets the customer specifications and/or process order scheduled.Perform furnace threading activities and strip stitching after a strip break or furnace service or repair.Perform furnace cleaning activities to maintain equipment, area or work stations organization.Responsible to coordinate all sections to help on the activities to drop pot gear and install air knives during start-ups or shut-downs.Adjust, monitor and control skin pass operation according to operation standard procedure in order to assure strip surface condition for the pre-painting process.Adjust, monitor and control tension leveler operation according to operation standard procedure in order to assure end product flatness meets customer and internal specifications.Responsible to lead work rolls, back-up rolls or cassettes changes on the skin pass mill and tension leveler.Responsible to assist with coater A or B roll change based on production schedule and following all the safety aspects.Responsible to condition and clean turn rolls and bridle rolls on the process section in order to eliminate dents during line operation or start-up process. Responsible to unload alloy trucks and properly store ingots into zinc warehouse according to operation procedure.Responsible to feed alloys into coating pots and make the proper consumptions into SAP according to practices.Fill up production logs or reports of their responsibility defined at the quality system.Participate actively during maintenance REX's to service and repair equipment designated by the head of sector and/or supervisor.Responsible to coordinate effective team communication between all sections (entry, process and exit) in order to assure line continuity.Monitor their workstations and assure their equipment is functioning properly at optimum conditions, if not, report it immediately to maintenance. Participate actively identifying unsafe conditions and report it immediately to his supervisor or head of sector.Participates in training programs, safety & technical courses at the times set by the company. Responsible to monitor chemical totes at mill and leveler. Change as needed.Responsible to assist coater operator with coater clean up.Tasks listed above are primary function. Operators are not limited to these functions and may need to perform additional tasks as required.SpecificFloaterThis position must perform all the tasks of Entry Operator Helper / Exit Operator Helper / Process Utility / Entry Operator / Lab. Exit Operator / Process Operator / Exit Inspector / Team Leader as needed.3. Competencies for the position:General CompetenciesComments:SafetyBasic Metallurgical ProcessesKnowledge of the Quality Management System (QMS)according to the training program in his area.Knowledge of Product Quality Testing: mechanical properties, coating weights and pre-treatment film weights4. Background Requirements:a. Education or Level of Education: Minimum level of formal education required for the positionSecondary: TechnicalUniversity: Higher:b. Professional Experience:Positions and minimum time required in each one to initially occupy the positionExperience: IndustrialMetallurgicalOperative Processes - Iron and steel or compatibleYears of experience:from 1 to 2 yearsLevel: c. Language (Other than local):Language proficiency (basic y expected) for the position (see level codes)Languages: NA