Machine Operator

The Buffering Associate is responsible for the setup of the buffering equipment and processing parameters for the manufacture of single fiber, multi-fiber and ribbon fiber buffer tubes. This includes setup of fiber, colorant, plastic, grease (jelly), and empty take-up bobbins/reels; performing quality checks (fiber/tube ratio, dimension measurements) to ensure the product being produced meets or exceeds both the customer's and OFS specifications.

The Buffering Associate monitors the line during manufacturing operation; performs routine and scheduled cleaning and TPM; performs basic troubleshooting; completes and records quality checks and manufacturing process data, and enters data into the Buffering data base.

Performs additional duties and task as assigned by Supervisor or Manager

CORE SKILL REQUIREMENTS:

JOB TITLE	READING	MATH	COMPUTER
Buffering Associate	3	2	1

ESSENTIAL WORK CATEGORIES

The following describe the work categories associated with the essential duties and responsibilities of this job:

a) Machine Operation: Monitors the Buffering Line continuously to keep the line operating efficiently and effectively; checks, changes and maintains the operating levels of the compound hopper, colorant and grease (jelly). Adjust such variables as line speed, extruder speed, temperature, grease, water, and fiber tension. Completes processing data requirements, quality checks (diameter, wall thickness, fiber & tube color and fiber to tube ratio; enters information into database. Plans changeovers and collects needed tooling, fiber and empty bobbins/reels.

Time Spent per 8-Hour Day: 65%

Frequency: Many Times Per Day

Significance: A most significant part of the job.

b) Machine Setup: Clean out the line and perform minor production maintenance - this includes purging the extruder (color change if required), cleaning extruder tooling and eyelets.

Review machine setup information and factory order. Collect fiber and ensure all materials needed are available for the upcoming run (colorant, plastic, grease). Load fiber onto payoffs and scan into database; string up fiber to the entrance of the extruder crosshead. Enter required operating data through touch screen or manual entry. Turn on extruder and string plastic tube (no fiber) from extruder crosshead through water trough and attach to empty bobbin at take-up. Ensure all operating set points and parameters are correct (jelly, extruder temperature, water, layer wind); speed up machine until diameter reaches specification as recorded by the Target gauge; insert fiber, check diameter and reset counter to record length, place knockout die in place.

Monitor line and all line components, run tube until completion of pre determined length.

Once a week the extruder is disassembled, the parts cleaned replaced and reassembled. The machine is inspected and any maintenance needs corrected at this time.

Time Spent per 8-Hour Day: 25%

Frequency: Many Times Per Day

Significance: A most significant part of the job.

c) Miscellaneous: Cleans, sets up and operates the buffer striping extruder to apply a black or white stripe to the tube as specified by factory order.

Once a week on a shift rotating basis disassemblies the extruder crosshead, changes screens in the screen pack, pull and clean extruder screw and barrel. Performs daily cleaning and organizing of the work area and daily, weekly, monthly TPM items as outlined in the TPM Checklist. During slow times or maintenance down time will be required to operate the fiber scrapping machine or rewind tubes as needed.

Time Spent per 8-Hour Day: 10%

Frequency: One or more times per week.

Significance: A routine part of the job.

Summary of Minimum Skill Level Requirements

Job Title	Gen Skill	Read	Write	Verb	List	Math	Reas	Comp
Buffering Associate	4	3	2	3	3	2	4	1

Special Considerations: Due to the cost and competitiveness of the fiber optic industry extra emphasis must be placed on producing a quality product at the lowest cost possible; reduction of loss due to fiber breaks and reduction of materials scrap by better planning and utilization.

Emphasis will be placed on improving computer skills due to the implementation of the SAP production tracking system.

General Skill Requirements:

The overall level of skill competency, which describe the requirements of this job:

Level Four: Ability to use all foundation skills necessary and apply them in a number of standardized work situations, and a few non-standardized situations, which are associated with the high profile nature of operating the buffering line. Fiber breaks and production miscues that cause remakes, can be expensive and can slow or shutdown plant production. When these situations occur the job can be very stressful.

Standardized situations require performing routine tasks over and over again to set procedures, sequence, and pace. Sometimes this routine can make the operator complacent, and this can lead to incorrect setups or failure to make necessary adjustments.

The Buffering Operator is required to make evaluations and judgments based on subjective and objective criteria. The Buffer Associate must have the ability and composure to quickly take necessary corrective actions, when problems occur, to avoid loss of production time and materials.

To gain a better understanding of the cable manufacturing process the Buffering Associate must develop knowledge of other related jobs in the department. The Buffering Associate also must have a broad knowledge of such functions as report preparation/data entry, work flow and measurement systems.

Interpersonal skills relating to teamwork and behavior are also essential. The Buffering Associate must have the aptitude and skills to fully participate in a teamwork environment.

Foundation Skill Competency Requirements:

a) Reading

Level Three: Read and comprehend a variety of basic business documents such as; procedures, operation instructions (OI's), production change notices (PCN's), design/setup information, routine business correspondence, and apply information in a variety of standardized job situations. Distinguish between essential and nonessential information.

b) Writing

Level Two: Write simple standardized business notes and memos with complete sentences, paragraphs, headings, salutation, and close; with correct capitalization of names of places, persons, days, months, years, and titles; with correct use of singular and plural forms; with punctuation including apostrophe, hyphen, and colon. Use good English grammar, correct spelling, and selection of words to express thoughts clearly.

c) Verbal

Level Three: Analyze facts and opinions and extract central theme and ideas. Use this information to speak to small associated work groups with confidence; with the ability to interact with the group.

d) Listening

Level Three: Must listen closely to detailed instructions, which are important to the job, with enough understanding to perform the hob correctly. Responsible for coordination of oral instruction with others who are dependent on receiving accurate information.

e) Mathematics

Level Two: Add, subtract, multiply, and divide units of measure with two and three digit multiplier and divisors; compute ratio, rate, and percent; draw and interpret bar graphs; work with the metric system.

f) Reasoning

Level Four: Ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagrammatic form; to deal with problems involving several concrete variables relating to a variety of job situations.

g) Computer

Level One: Basic use of a computer involving signing on/off the system; selecting screens by function key, touch screen, or mouse; entering limited data from a keyboard such as numbers, simple words, selection of options and machine setup information from predefined tables/screens. Use of computer terminals such as bar code scanners.

Education, and Certification:

High School or Equivalent.
Core skill level (TABE) requirements as listed.
Completion of certification in all aspects of the job.

On-the-Job Experience and Training Requirements:

Supervised on-the-job training of 6 weeks under the direction of a trainer, and Supervisor. Mastery of the complete buffering operation including troubleshooting generally occurs within 6 months.

General Aptitude Levels:

a) Verbal

Level Four: Ability to understand statements of operations and procedural routines; to discuss objectives and output requirements with team leaders.

b) Numerical Aptitude

Level Two: Ability to measure height width; add totals; determine temperatures, time, and weight.

c) Spatial Aptitude

Level Three: Ability to observe the relationship between a moving load and fixed items; to think in geometric terms; to visualize and set up patterns.

d) Form Perception Aptitude

Level Four: Ability to accurately read measuring instruments such as pin gauges, calipers; to observe the effect of color, light and shade.

e) Clerical Perception Aptitude

Level Three: Ability to complete forms such as requisitions; to record and locate data accurately; to reconcile two columns of data.

f) Motor Coordination Aptitude

Level Three: Ability to coordinate finger, eye, and hand with speed such as when typing; to manipulate items quickly such as in a production line environment.

g) Finger Dexterity Aptitude

Level Three: Ability to manipulate hand tools such as knives, scissors, screwdriver, and computer mouse.

h) Manual Dexterity Aptitude

Level Three: Ability to use one hand for twisting and turning motion while coordinating other hand with different activities.

i) Eye-Hand-Foot Coordination Aptitude

Level Two: Ability to coordinate hand and foot with vision to physically position material prior to an operation.

j) Color Discrimination Aptitude

Level Three: Ability to match colors in terms of hue, saturation, and brilliance; to distinguish between different shades and color.

WORK AIDS

Machines, tools, equipment, and other work aids, which may be representative but not all inclusive, of those, associated with this job.

Hand Tools	Calipers	Calculator
Pin Gauge	Tension Gauge	Ultrasonic Cleaner
Buffer Line Equipment	Computer & Scanner	Tape Measure
Buffering Raw Materials	Bobbins	Plug Gauges

ENVIRONMENTAL WORKING CONDITIONS

a) Noise Intensity Level

Level Three: Medium -- Business office where computers, typewriters and other office equipment are used; light manufacturing.

OTHER ENVIRONMENTAL CONDITIONS:

Code		Frequency		Definition
N		Negligible		Not associated with this job
O		Occasionally		Condition exists up to 1/3 of the time.
B		Frequently		Condition exists 1/1 to 2/3 of the time.
C		Constantly		Condition Exists 2/3 or more of the time.

b) Exposure to Weather: N

Exposure to outside atmospheric conditions.

c) Extreme Cold: N

Exposure to non-weather related cold temperature.

d) Extreme Heat: C

Exposure to non-weather related hot temperatures from extruder, water trough.

e) Wet and /or Humid: F

Contact with water or other liquids or exposure to non-weather related humid conditions.

f) Vibration: N

Exposure to a shaking object or surface.

g) Atmospheric Conditions: O

Exposure to conditions such as fumes from plastic and color concentrates, ultrasonic cleaner that affect the respiratory system, eyes, or skin.

h) Proximity to moving Mechanical Parts: F

Exposure to possible bodily injury from moving mechanical parts of equipment, tools, or machinery.

i) Exposure to Electrical Shock: O

Exposure to possible electrical shock.

j) Working in High, Exposed Places: N

Exposure to possible bodily injury from falling.

k) Exposure to Radiation: N

Exposure to possible bodily injury from radiation.

l) Working with Explosives: N

Exposure to possible bodily injury from explosives.

m) Exposure to Toxic/Caustic Chemicals: O

Exposure to possible bodily injury from toxic or caustic chemicals. For example, color concentrate, and cleaning solutions.

n) Exposure to Biological Hazards: N

Exposure to possible contamination or harm from fungi, bacteria, or viruses.

o) Other N

Other environmental conditions, not defined above.

PHYSICAL DEMANDS:

Type and degree of physical strength associated with this job.

Light Heavy

Level Three: Medium Work - Exerting up to 20 to 50 pounds of force occasionally, or 10 to 25 pounds of force frequently, or up to 10 pounds of force constantly to move objects. Items lifted are spools of fiber, color concentrate barrels, extruder screw and crosshead.

Physical Requirements:

Working position: The Buffering Associate walks up and down the line about 60% of the time; stands about 40% of the time while loading fiber, monitoring machine controls, input of data, and making quality checks.

The following categories are the types of physical requirements associated with the jobs. The frequency requirement scale is:

CODE FREQUENCY

CODE		FREQUENCY
N		Never
O		Occasionally
F		Frequently
C		Constantly

a) Climbing: F

Ascending or descending ladders, stairs, ramps, and the like, using feet and legs or hands and arms. Body agility is emphasized

b) Balancing: O

Maintaining body equilibrium to prevent falling when walking, standing, crouching, or moving non-narrow, slippery, or erratically moving surfaces.

c) Stooping: O

Bending body downward and forward by bending spine at the waist, requiring full use of the lower extremities and back muscles.

d) Kneeling: O

Bending legs at the knee to come to rest on knee or knees.

e) Crouching: O

Bending the body downward and forward by bending legs and spine.

f) Crawling: N

Moving about on hands and knees or hands and feet.

g) Reaching: F

Extending hand (s) and arm (s) in any direction.

h) Handling: F

Seizing, holding, gasping, turning, or otherwise working with hand or hands. Fingers are involved only to the extent that they are an extension of the hand, such as to turn a switch.

i) Fingering: F

Picking, pinching, or otherwise working with primarily the fingers rather than with the whole hand or arm as in handling.

j) Feeling: O

Perceiving attributes of objects such as size, shape, temperature, or texture by touching with skin, particularly that of the fingertips.

k) Talking: F

Expressing or exchanging ideas by means of the spoken word to impart oral information to team members, team leaders, engineers or other employees.

l) Hearing: C

Perceiving the nature of sounds by ear.

m) Tasting: N

Distinguishing, with a degree of accuracy, differences or similarities in intensity of quality of flavors, or recognizing particular flavors, using the tongue.

n) Smelling: N

Distinguishing, with a degree of accuracy, differences or similarities in intensity or quality of odors, or recognizing particular odors, using the nose.

o) Near Acuity: F

Clarity of vision at 20 inches or less.

p) Far Acuity: F

Clarity of vision at 20 feet or more.

q) Depth Perception: O

Ability to judge distance, space relationships, and three-dimensional perception so as to see objects where and as they actually are.

r) Eye Accommodation: F

Adjustment of the eye to bring an object into sharp focus. Especially important when doing near point work at varying distances from the eye.

s) Color Vision: F

Ability to identify and distinguish colors.

t) Field of Vision: F

Observing an area that can be seen up and down or to the right or left while eyes are fixed on a given point.

u) Other Physical Demands: N

Other physical demands, not defined.

Employees are expected to serve as role models for safe work practices and behaviors. This includes following established health and safety policies and procedures, maintaining a clean, organized work area, wearing, and properly storing all personal protective equipment (PPE), and actively engaging as a safety conscious worker with personal safety and wellness as a priority.