General Machine Operator
Competency-based
ONET: 51-4081.00
1
Years
152
Skills
142h
Related instructions
Classroom instruction topics
- Alabama Career Essentials (ACE) - Computer Literacy
- Safety Training
- Alabama Career Essentials (ACE) - Math for Work
- Onboarding
- Alabama Career Essentials (ACE) - Financial Literacy
- Alabama Career Essentials (ACE) - Communication
- Alabama Career Essentials (ACE) - Workplace Etiquette
- Alabama Career Essentials (ACE) - Resolving Problems in the Workplace
- Alabama Career Essentials (ACE) - Healthy Workplace Environment
- Alabama Career Essentials (ACE) - Employment Preparation
- Alabama Career Essentials (ACE) - Workplace Safety
- National Career Readiness Certificate (Workkeys)
- OSHA 10 - General Industry
- MSSC Safety
- MSSC Certified Logistics Associate (CLA)
- FEMA Active Shooter
- Mobilizing Alabama Pathways (MAP) - Manufacturing
- First Aid/CPR
On-the-job training
- Dry End Training - General Safety
- Complete OSHA compliance training requirements: Bloodborne pathogens, Electrical awareness, Emergency action plan, Hazard communications, PPE, and Forklift awareness
- Complete Saint-Gobain's CertainTeed EHS training
- General Equipment Operation
- Operate forklifts
- Operate pole trucks
- Operate Bobcats
- Operate lulls
- Operate floor scrubbers
- 5S Standardization for Core Cutting Area
- Demonstrate satisfactory 5S tool and equipment storage
- Demonstrate satisfactory 5S pallet storage, core storage, and box storage
- Use check lists, score sheets, and activity boards
- Core Locations, Storage, and Transport
- Describe all required storage rack locations
- Describe all required trailer locations and perform unloading Mondays and Tuesdays
- Scrape core and boxes loading on Thursday nights
- Core Cutter
- Identify safety features (E-stops, Guards)
- Demonstrate lockout points of equipment
- Explain basic functions of the Core Cutter
- Load cores on table and machine
- Calculate and cut 30 cores to specified length
- Stage and band cores
- Load 6 pallet of cores onto core rack
- Lockout machine change blade and test
- Load core trailer with scrap (4x)
- Clean area/housekeeping
- 5S Standardization for Wrapping Operation
- Use 5S for tools and equipment storage
- Practice 5S for plastic wrap and tape storage, location
- Use check lists, score sheets, activity boards
- Wrapper
- Identify safety features (E-stops, Guards)
- Use lockout points of the wrapper
- Use basic functions of the Wrapper
- Use controls and demonstrate how to operate conveyors
- Demonstrate how to operate drop gates
- Inspect 10 finished roll, for defects, telescoping (no more than 1⁄2"), tickets, directional tape pointing in correct direction, no damage to roll and place end cap
- Successfully operate wrapper and wrap 10 rolls without assistance
- Successful transfer rolls from roll table to take conveyor
- Successful load and process 6 rolls from the Rewinder
- Wrapper Crane Function
- Use crane safety devices
- Crane handset storage and button function
- Perform crane visual inspection for defects
- Perform plastic wrap loading while using crane
- Conduct Plastic Wrap thread up without assistance
- Replace tape on Wrapper head without assistance
- Take Off Operations
- Successfully unload 10 roll from takeoff station
- Login to tablet and scan 10 rolls from take off
- Successfully identify and bin locations and scan 10 rolls to correct bin location
- Stage 10 Rolls in the warehouse without damaging product
- Cannonball 10 Rolls in the warehouse without damaging product
- Load and unload Rewinder operator rolls as requested
- Winder Support
- Identify safety features (E-stops, Mat, Pull Cord, Light Curtin and Gate Switches )
- Use lockout points for Winder
- Review Winder Operations and functions
- Load cores on winder core table in accordance with production order requirements ensuring cores meet required specification with no more than 1/8th of an inch deviation
- Successfully setup mandrel for operations on 10 turn ups without misalignment
- Successfully operate mandrel dead man switch for roll processing
- Successfully process roll by applying directional tape, ticket, etc. on 10 finished or rewind roll
- Successfully perform 4 roll cut downs without assistance
- Quality Inspector Training - Computer Skills
- Locate SQCPack and open needed files
- Locate and enter information in WW report
- Create a new Whitewater Report
- Complete the Dr Schenk Cleanliness Check
- Print more lab forms as needed
- Whitewater Testing
- Collect whitewater samples & determines how much is needed for testing
- Collect Visc. Modifier samples & determine how much is needed for testing
- Operate viscometers from the OFF position
- Determine speed WW viscosity should be tested
- Locate & mix Tracide chemicals
- Perform WW Viscosity test w/o assistance
- Perform conductivity tests on WW and Viscosity Modifier
- Operate Tracide & perform Tracide test without assistance
- Operate pH meter & perform pH yest without assistance
- Record WW test results in SQCPack and Whitewater Report
- Mat Testing
- Read and describe product specifications
- Explain reasons for testing frequency
- Read a tape measure
- Perform Start-Up & Changeover testing requirements
- Layout samples on position table regarding trim offset and mark positions
- Cutout test samples without assistance
- Perform met testing and record results on spreadsheet
- Enter test results in SQCPack in the proper files
- Obtain calculated test results in an upset condition SQCPack is down
- Identify rolls that are out of spec and pace on hold
- Binder Testing
- Safely obtain the Binder sample from the Saturator
- Perform Binder testing without assistance
- Identify the correct pH probe to use for Binder
- Record Binder test results in SQCPack
- Fiber Testing
- Obtain fiber samples and record needed information from fiber label
- Perform fiber test without assistance
- Measure the correct amount of fiber used for testing
- Safely remove fiber samples from oven & furnace
- Record fiber test results in the appropriate SQCPack file
- Resin Testing
- Safely collect the Resin sample in the appropriate amount
- Collect the COA from the driver
- Identify the correct pH probe to use for resin
- Perform Resin testing without assistance
- Follow procedure to save a sample in the lab fridge properly labeled
- Use the water circulator @ 25 degrees Celsius
- Latex Testing
- Safely collect the Latex sample in the appropriate amount
- Follow procedure to collect the COA from the driver
- Identify the correct pH probe to use for latex
- Perform Latex testing without assistance
- Follow procedure to save a sample in the lab fridge properly labelled
- Operator water circulator at correct temperature (25°C)
- Lab Start Up and Shut Down Procedure
- Turn lab computer on & off successfully
- Turn water bath on or off
- Turn on & off viscometers, pH meter
- Properly turn on & off LOI furnaces
- Winder Backup Operator Training - 5S Standardization for Winder Area
- Use 5S for tools, equipment, storage, and trash
- Use check lists, score sheets, and activity boards
- Use 5S for roll tape storage and preparation
- Use 5S for printer ribbon and tape storage
- Winder Machine Cutter
- Review and identify (4) Machine / Components and function
- Conduct mandrel inspection for leaks and damage
- Successfully inspect slitter station and change 6 slitter blades to include installation of slitter guards during while equipment down
- Start Up Operations
- Successfully cut tail and thread up on 6 startups
- Successfully set trim chute and engage trim blades on 6 startups
- Lead and assist in cleanup during failed startup attempts
- Documents
- Maintain up-to-date and accurate reporting on slitter report
- Maintain accurate core audits on core sheet
- Manually track finished production as required (Winder Report)
- Identify defects with vision system and Process three Rewind Rolls (list rolls in comments)
- Identify defects with vision system and Process three Scrap Rolls (list rolls number in comments)
- Process six rolls with name listed as name on tickets (list rolls in comments)
- Winder Fill-In
- Relieve winder operator during 8 breaks without disruption of production
- Fill in as Winder operator for at least two full shifts without disruption in production
- White Water Training - Dispersants
- Describe dispersants, their characteristics, and their uses
- Classify the properties of dispersants
- Explain the process and actions of dispersants
- Describe the pros/cons of dispersants
- Viscosity Modifier
- Describe viscosity modifiers, their uses, properties, and characteristics
- Explain procedures and use of Liquid Inverse Emulsion
- Explain procedures and use of Dry Powder
- Explain procedures and use of Solutions
- Control variability by using the correct viscosity modifiers
- Defoamers
- List the 5 main defoamer classes and describe the differences between each class
- Describe the composition of defoamers/antifoamer compounds
- List the foam control additive properties
- Explain why defoamers are needed in the process
- Describe the generic Glass Mat process from start to finish
- Detail the causes of foaming in mat manufacturing
- Explain the reason/process for using defoamer in the following: Whitewater, Binder systems, and Auxiliary functions
- List the considerations for using defoamer in: Whitewater, Binder systems, and Auxiliary functions
- Describe the potential issues with defoamers
- Discuss conditions impacting the growth of microbes in White Water
- Detail White Water issue caused by bacterial growth
- Biocides
- List the 2 types of biocides and the properties of each
- Name and describe the 3 types of microbiological monitoring
- Troubleshooting White Water Chemicals
- Troubleshoot dispersants to correct under/overfeed conditions
- Troubleshoot viscosity modifiers to correct under/overfeed and low viscosity conditions
- Troubleshoot high/low pH levels of the White Water
- Verify condition of process tanks
- Troubleshoot pump and piping issues
- Perform regular testing of White Water
- Rebuild White Water
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