DPF Operator I - A Shift - 7:30am - 7:45pm - ( 4 on 4 off )

NGK Ceramics USA, Inc.; Mooresville (NC); On-site; USD 38,000 - 52,000; Full time

Job summary

NGK Ceramics USA, Inc. in Mooresville, NC seeks a production associate to operate and monitor the sifting, weighing, silo filling, and bulk unloading processes. You will ensure correct particle sizes, verify materials, and support batch production within quality specs.

The role requires attention to detail, safety orientation, and teamwork; prior manufacturing/warehousing exposure is helpful. PPE must be worn; the job emphasizes accurate data entry and routine testing like CILAS.

Qualifications

• High school diploma or GED required; CRC Bronze or higher preferred.
• Experience in manufacturing/warehousing is preferred.
• Basic MS Windows software skills are a plus.

Responsibilities

• Operate and monitor sifting, weighing, silo filling and bulk unload processes.
• Verify material types, lot numbers and batch records per procedures.
• Collect samples and perform CILAS particle size tests; report out-of-bounds results.
• Maintain clean work areas, observe PPE requirements and safety protocols.
• Document data in information systems and assist with inventory processes.

Skills

Safety orientation

Teamwork

Attention to detail

Reading procedures

Problem solving

Communication skills

Environmental awareness

CILAS testing knowledge

Education

High school diploma or GED

CRC Bronze or above

Certified Production Technician (preferred)

Tools

MS Windows

Forklift license

Job description

Position Summary

Operates and monitors the sifting process, which ensures that the raw materials are processed to the correct particle size specifications; operates and monitors the department's weighing line processes; replenishes and maintains sufficient levels of materials in the weighing silos and in the material staging areas; and operates and monitors the bulk unloading process, which involves unloading raw materials from railcars into the bulk silos; all of which enable the safe and efficient production of completed weigh batches, which are used in the manufacturing process.

Essential Duties and Responsibilities

Sifting duties

• Monitors weighing silo levels to determine shift production requirements.
• Obtains raw materials from on‑site warehouse after verifying material type and raw material lot number using the Lot Designation Sheet.
• Vacuum the outside of raw material bags to ensure no debris or contaminants are introduced into sifters or weighing silos.
• Retrieve manufacturer’s information from bags before processing; position bag above hopper by using a hoist; untie and attach spout of bag to hopper opening; and empty bag into hopper.
• Verify that sifter screens are in good condition prior to processing; charge and process material lots in accordance with company’s work instructions; and check sifter screens’ condition after each processed lot.
• Obtain samples from processed lots for testing and lab analysis.
• Perform CILAS machine particle size test on samples from each processed lot and notify Technical Leader or Supervisor if test results are outside of specifications.
• Input processed lot data and CILAS test results into the company’s information systems; and take samples to the Material Control Lab for analysis.
• Prepare transport setup to the correct weighing silo for Technical Leader’s approval and transportation.
• Build, remove and replace sifter screens and blades as required.

Weighing duties

• Check outside dust collectors and replace bags when full; and clean weighing silo magnets when required.
• Verify that the correct order number and the correct starting weigh batch number are selected on the computer before starting the weighing process.
• Ensure weighing racks are clean; radio frequency identification (RFID) tags are secured; and that super sacks are properly attached to the racks.
• Monitor the weighing line process, report errors or discrepancies to the Technical Leader or Supervisor, and check weigh batch tickets to confirm all weigh batches are within specifications.
• Write batch numbers on sides of super sacks; write body name and batch numbers on the front and back of the super sacks; tie the tops of the super sacks securely; and double‑stack weighed batches onto export pallets and load onto rack system.
• Prepare cardboard box containers (for 2000 weighing line) and place the boxes on the proper pallets; prepares weigh batch barrels for weighing by lining barrels with the appropriate bags.
• Check weigh batch tickets to confirm that all weigh batches are within specifications; secure tops of bags with zip‑tie fasteners; weigh each batch on scale to reconfirm actual weights; and write batch data on log before placing weigh batches in boxes.
• Write enclosed batch number range on all four sides and also write body name on front and back of box container; place lid on filled container and tape securely; and stack boxes/pallets on floor in prescribed areas.

Silo Filling duties

• Verify body code being weighed and check computer (AZO visual) and silo diagram levels to determine which materials need staged for filling into silos.
• Obtain raw materials from on‑site warehouse after verifying material type and raw material lot number using the Lot Designation Sheet; and vacuum the outside of the raw material bags to prevent contamination.
• Print bar codes for each bag of material with the correct product name, raw material lot number, and weight; transport single bags on plastic pallets and stage near elevator for a co‑worker to send upstairs via the elevator; and stage correct materials in front of silo filling stations.
• Open dust collection valves at silo filling stations; and select appropriate silo for filling on the computer display touch screen.
• Confirm that the bar code ticket and manufacturer’s information on the raw material bag matches the silo to be filled; and operate hoist to lift material bag onto the silo filling station.
• Scan the bar code to unlock silo cover; remove the silo cover; untie the material bag; empty the bag into the silo; and replace the cover.
• Select “stop filling” on the computer display touch screen to update inventory levels in the system; and complete the paperwork (silo filling worksheet) for each lot of material that is dumped into the silos.
• Wear the proper personal protective equipment (PPE) in the designated areas (e.g., respirator).

Bulk Unload duties

• Perform a system check and setup in preparation for the transfer of bulk rail materials.
• Verify all railcar numbers in the yard.
• Inspect the railcars and ensure the proper settings of valves and petcocks.
• Verify that the raw material lot numbers for each incoming bulk rail material match the Lot Designation Sheet.
• Prepare hoses for transfer of raw materials in accordance with work instructions.
• Confirm correct hose connections by examining the corresponding indicator lights on the control panel.
• Transfer the bulk rail materials to the correct bulk silos.
• Regulate blower pressure and railcar pressure while transferring bulk rail materials.
• Obtain material samples during raw material transfer.
• Perform CILAS machine particle size test on samples obtained during raw material transfer.
• Input sampling data into the appropriate QSI Infinity project.
• Notify area management if particle size data falls outside of upper or lower control limits.
• Verify that the railcars are empty and perform the proper shut‑down procedures when the raw material transfer is finished.
• Adhere to “Quiet Time Zone” procedures.
• Unclog raw material lines as needed.

Additional duties

• Work safely by avoiding forklifts; staying clear of forklift doors; using personnel doors when entering or exiting the buildings; and safely using overhead hoists.
• Participate in preventive maintenance (PM), machine maintenance operator leader (MMOL) and G5S (Global 5S) activities as needed.
• Follow all environmental management system (EMS) procedures, including the disposal of waste and used materials.
• This job has no supervisory responsibilities.

Required Competencies

Customer focus; environmental awareness and compliance; functional & technical expertise and computer skills; integrity and accountability; organizational awareness; respect and humility; safety orientation; teamwork.

Required and Preferred Qualifications

Required Education and/or Experience

• Must be able to successfully complete all required job training.
• High school diploma or general education degree (GED).
• Six months manufacturing/warehousing experience or equivalent.
• CRC Bronze or above.
• Certified Production Technician program completion (preferred).

Required Language Skills

Ability to read and interpret documents such as safety rules, operating and maintenance instructions, and procedure manuals.

Required Mathematical Skills

Ability to add and subtract, multiply and divide in all units of measure, using whole numbers, common fractions, and decimals.

Required Reasoning Ability

• Ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form.
• Ability to deal with problems involving several concrete variables in standardized situations.

Preferred Qualifications

• Basic MS Windows software skills.
• Forklift license and pallet jack license.

Physical Demands

While performing the duties of this job, the employee is regularly required to stand; walk; use hands to finger, handle, or feel; reach with hands and arms; climb or balance; and talk and hear. The employee is frequently required to stoop, kneel, or crouch. The employee must frequently lift and/or move up to 50 pounds. The employee must successfully pass scheduled testing for respirator fitting and spirometry.

Work Environment

• While performing the duties of this job, the employee is regularly exposed to moving mechanical parts; frequently exposed to airborne particles; and occasionally exposed to extreme cold; outdoor weather conditions; and vibration.
• The noise level in the work environment is usually moderate and occasionally loud.

Safety Requirements / PPE

• Safety shoes must be worn while on NGK property.
• Hearing protection and safety glasses are required in designated areas.
• Respirators are required in designated areas or under prescribed work conditions.
• Regularly scheduled testing is performed for lung capacity (spirometry test), hearing, and respirator fit.

Employment Disclaimer

• This job description is not to be considered a written contract. Employment with NGK is at will. This means that the employee, as well as the company, is free to terminate the employment relationship at any time and for any reason not prohibited by law. Also, this job description is not designed to be a complete listing of the tasks, duties or responsibilities that are required of the employee.