Front End Operator Cum Maintainer

Further your career at Ball, a world leader in manufacturing sustainable aluminum packaging. Achieve extraordinary things when you join our team, and make a difference in your professional development, the community, and around the globe!

Ball is thrilled to receive Newsweek's 2023 Top 100 Global Most Loved Workplace award! As a sustainable product leader, we have over 16,000 global team members. From endlessly recyclable aluminum cans, and cups, to aerosol bottles, our goal is to contribute to a better community, society, and world.

Reporting to – Shift Manager

Purpose of the role:

Front End Operator cum maintainer is key member of shift operation team and his primary role is to focus on OEE of front end Equipment in can making line. He will focus on operation, process and maintenance issues of Process equipment in the front end namely Cupper, Bodymakers & trimmers and take corrective actions on time during his shift. He will focus on Daily operation, Periodic inspection and maintenance, predictive maintenance and corrective Maintenance activities in front end. He will gain mastery in Process troubleshooting and maintenance of Cupper Bodymakers and trimmers. He will work with team and co-ordinate all the activities of Maintenance, improvements, TPM, 5’s QC Check activities in the area. He will strive hard to achieve area KPI’s through collaboration, teamwork and planning. He will play key role in size changeovers and achieve best in class changeover time in the front end

Essential Responsible Areas

• Responsible of Operation and maintenance of Front end equipment. He will ensure the front end Machines are utilized and operated to their optimum speed and efficiency.
• Ensure power press Safety checks are completed within first two hours of shift on Both Cuppers and Bodymaker. Ensure actions are taken on time to close the deviation.
• Ensure daily Operation / Maintenance checks are done in the front-end and corrective actions are taken on time. If any support is needed, ensure to escalate to proper level and close the open items.
• Ensure the cans produced in front end meet all quality specification. Ensure Quality checks are completed and corrective actions are taken on time for any deviation. Responsible for CCP- Sliver in Trimmers. Ensure proper procedure / measures are followed in his shift to control the CCP.
• Ensure front End area and Equipment are maintained in accordance with housekeeping and hygiene standard. Ensure Housekeeping is maintained during shift hours and handover shift with good housekeeping.
• Beginning of shift take the handover from the outgoing operator, understand the issues in the area, and plan follow up / support needed from his team and engineering resources. Ensure to receive the area with proper housekeeping, all scrap bin cleared and scrap is counted.
• Responsible for front end area spoilage target. Ensure to address the spoilage concerns (tipped cans / Jams) and take swift action to get the abnormal condition back on track.
• Check for tool usage in Bodymaker. Work closely with toolroom for tools replacement on periodical basis. Polish / crosshatch Bodymaker tooling as per schedule.
• Responsible for short can rate in Bodymaker. Ensure to check process parameters (Cup quality, Cup lube level, Tramp oil level, coolant concentration, Coolant temperature) are within specification. Troubleshoot equipment for short can issues and seek help if needed from Engineering.
• Gain Mastery and Execute coil change with SMED concept. Ensure die set / cupper is cleaned and maintained on periodical basis.
• Utilize the opportunities (Standby time, label change time or any other natural downtime) to plan for Corrective maintenance activity in Bodymaker and cuppers (such as filter change, Stripper change and seal changes).
• Safety: Near miss reporting. Attends all safety trainings. Part of plant emergency management team. Can manage emergencies and act as key resource in shift for plant evacuation for fire alarm or other Emergency situations.
• Responsible for all the standard and special tools for his shift. Ensures effective utilization of tools and tackles and prevent misuse of same.
• Work closely with Front and Area engineering resource and allocate his team resources for proper Maintenance and up-keeping of front end equipment.
• Understand solid waste management system. Ensure all the waste generated in the area are segregated / handles and disposed-off according to the system.
• Beginning of shift take the handover from the outgoing shift team, understand the issues in the area, and plan follow up / support needed from his team and engineering resources. Ensure to receive the area with proper housekeeping, all scrap bin cleared and scrap is counted.
• Actively participate in companies Continuous Improvement initiatives e.g. Lean Manufacturing, Six Sigma, SMED, 5S, ISO, etc. Conduct lean manufacturing activities and participate in audits as per company requirements. Attend area team meetings on periodical basis. Drives area improvement agenda based on meeting outcomes.
• Gain mastery in Bodymaker and trimmer periodic maintenance. Support engineering resources for periodic maintenance.
• Gain mastery in audit and alignment of Bodymaker. Support engineering resources for periodic maintenance.
• Work closely with engineering resources for changeover activities. Gain mastery in die set change / Bodymaker changeover, trimmer changeovers.
• Ensure Team leader / front end log book is updated. Note down the corrective action taken in the shift and action list for the support needed from engineering resources to action upon.
• Responsible for hydraulic oil consumption in the front end in his shift. Changes ram seals / pushrod seals or any other corrective actions for deviations.
• Responsible for corrective Maintenance on front end during his shift, either attend personally or allocates resources, and get the equipment back in operation with least possible downtime.
• Gives input for spare parts stores / front end engineering resources for consumables, machine spares and tools consumption and help achieve maintenance spending target.
• Follows and maintain organization’s SOPs and safe working practices. Comply with any legal, environmental and safety, BRC requirements and/or checks.
• Sga
• Responsible for Planning of and execution of preventive Maintenance activities in Cupper Bodymakers and trimmers. Tracks the maintenance compliance on periodical basis and take corrective actions to bridge the gap
• Checks and control critical process indicators in front end such as tramp oil concentration, coolant concentration, short can rate etc., and take timely actions to highlight and correct it.
• Responsible for corrective Maintenance on front end, either attend personally or allocates resources, and get the equipment back in operation with least possible downtime.
• Responsible for Size changeovers in cupper, Bodymakers and trimmers. Organizes and inspect change parts prior to changeovers. Plan and organize resources to ensure Size change is done within specified time and up in running smoothly with least issues.

Specific Responsible Area

• Meet Production, maintenance, Quality, Spoilage and environmental improvement targets as set by the Shift Manager, the Continuous Improvement teams and the Plant budget.
• Investigate/Report equipment/process defects/HFI promptly and use the team and outside assistance to identify and undertake corrective action to prevent re-occurrence.

Professional & Education Qualification

Diploma in Mechanical engineering or Toolroom technology or ITI any trade 6 to 10 Years maintenance / repair experience in manufacturing background in a high speed, high volume continuous process plant with hydraulic and Mechanical presses

Knowledge & Skill

• Must be able to work shifts and able to work extended hours on occasions when required.
• Computer literacy and the ability to generate reports. Ability to read, understand and develop engineering drawings.
• Analytical skills to interpret numerical data.
• Working knowledge of Health and Safety work practices.
• Basic mechanical knowledge required
• Basic measuring equipment knowledge
• Good computer skills – ability to manage via computerized data
• Working knowledge of Health and Safety work practices
• Manufacturing background in a high speed, high volume continuous process

Ball Corporation is an Equal Opportunity Employer. We actively encourage applications from everybody, regardless of gender, age, ethnicity, faith, ability, or orientation.

When you join Ball you belong to a team of over 16,000 members worldwide. Our products range from infinitely recyclable aluminum cans, cups to aerosol bottles that enable our customers to contribute to a better world.

Each of us has a deep commitment to diversity and inclusion which is the foundation of our culture of belonging. Everyone at Ball is making a difference by doing what we love. Because what we create may change, but what we will always make is a difference.

Please note the advertised job title might vary from the job title on the contract due to local job title structure and global HR systems.

No agencies please.