Setup Process Technician

Radius Packaging; Delavan (WI); On-site; USD 44,000 - 50,000; Full time

Job summary

Radius Packaging in Delavan, WI is seeking a Setup Process Technician to lead mold changes, machine setups, and startup activities in blow molding and injection molding. You will work with Production, Maintenance, Engineering, and Quality to optimize processes, document parameters, and improve uptime.

The role emphasizes safety, continuous improvement, and reliability, with opportunities for training and career growth in a collaborative, award-winning culture.

Qualifications

• High School Diploma or GED required.
• Advanced technical certification or apprenticeship preferred.
• 3–5 years of machine setup or processing experience preferred.
• Experience with Blow Molding and Injection Molding preferred.
• Ability to read blueprints and process sheets.
• Flexibility to support 24/7 operations.

Responsibilities

• Perform mold changes, machine setups, and startup activities.
• Verify operation of molds, tooling, robotics, and cooling systems.
• Establish documented process parameters for safe, efficient production.
• Support changeovers and equipment readiness.
• Troubleshoot machine/process/tooling issues with root-cause analysis.
• Collaborate with Maintenance, Engineering, Quality, and Production.
• Follow safety, GMP, and food safety requirements.
• Maintain process sheets and setup standards.

Skills

Machine setup

Troubleshooting

Lean Manufacturing

SMED

Data-driven

Education

High School Diploma or GED

Tools

Mold tools

Robotic systems

Automation equipment

Job description

Job Details

Job Location: Delavan - Delavan, WI 53115

Position Type: Full Time

Education Level: High School

Salary Range: $32.00 - $36.00 Hourly

Travel Percentage: None

Job Shift: 1st Shift or 2nd Shift, M-F

Job Category: Skilled Labor - Trades

At Radius Packaging, we put people first—our members and our customers. Our culture is guided by The Radius Way: Champion Positive Change, Act with Integrity, Strive for Excellence, Emphasize Community, and Work Together. These principles shape how we lead, collaborate, and grow together.

We don’t just talk about culture—we’re recognized for it. Radius Packaging is proud to be honored as:

• Plastics News Processor of the Year — the industry’s highest distinction
• Top Workplace by the Milwaukee Journal Sentinel in 2024 and 2025
• Recipient of the Plastics News Excellence in Employee Relations Award

These recognitions reflect our commitment to continuing education, career advancement, employee recognition, and fostering a supportive, engaging work environment.

Celebrating over 53 years of success, Radius Packaging offers more than a job—we offer a community. Through educational resources, committees, clubs, and company-wide events, our members are supported in their professional growth and overall well-being—financial, mental, physical, and emotional. We continuously invest in our people and empower them to pursue their passions at work, at home, and in their communities.

If you’re looking for a workplace that values teamwork, innovation, sustainability, and personal growth, Radius Packaging is where you belong.

SUMMARY OF POSITION:

The Setup Process Technician serves as a key technical resource responsible for machine setups, mold changes, process optimization, troubleshooting, and equipment reliability within Blow Molding and Injection Molding operations. The role supports safe, efficient, and consistent production through effective startup activities, process control, root cause problem solving, continuous improvement initiatives, and collaboration with Production, Maintenance, Engineering, and Quality teams. The Setup Process Technician is expected to develop and maintain expertise in molding processes, tooling, equipment operation, and process stability to ensure the production of quality products delivered on time to customers.

JOB DUTIES & ESSENTIAL FUNCTIONS:

This list of duties and responsibilities is not all inclusive and may be expanded to include other duties and responsibilities, as management may deem necessary from time to time.

Equipment Setup, Changeover & Startup

• Perform mold changes, machine setups, job changeovers, and startup activities on blow molding and injection molding equipment.
• Set up and verify proper operation of molds, tooling, auxiliary equipment, robotic systems, cooling circuits, and secondary equipment.
• Establish, document, and maintain approved process parameters to support safe, efficient, and repeatable production.
• Complete startup verification, quality inspections, and process checks
• Support production schedules by ensuring timely and effective changeovers and equipment readiness. The role supports centerlining by establishing, validating, and sustaining documented machine centerline settings and process windows that drive repeatable startups, reduced scrap, and consistent equipment performance.

Process Control & Optimization

• Monitor and adjust processing parameters to maintain product quality, efficiency, and cycle time performance.
• Analyze processing conditions and machine performance to identify opportunities for productivity improvements and waste reduction.
• Evaluate current setup methods and processing practices and recommend improvements to improve reliability, quality, and throughput.
• Support mold trials, process validation activities, and new product launches through process monitoring and technical feedback.
• Assist in documenting and maintaining process sheets, setup standards, and operating parameters.

Troubleshooting & Technical Support

• Troubleshoot and resolve machine, process, tooling, automation, hydraulic, pneumatic, and auxiliary equipment issues.
• Utilize structured problem‑solving techniques including root cause analysis and 8D methodologies to identify and eliminate recurring issues.
• Analyze scrap, downtime, and process variation to determine root causes and support corrective actions.
• Work closely with Maintenance, Engineering, Quality, and Production teams to resolve equipment and process concerns.
• Provide technical analysis and documentation related to process, tooling, and equipment performance issues.

Maintenance & Equipment Reliability

• Perform preventive maintenance activities as assigned.
• Assist Maintenance in identifying, reporting, and correcting machine and equipment deficiencies.
• Maintain setup tools, molds, support equipment, and process documentation in an organized and ready condition.
• Support equipment reliability improvement initiatives and tooling enhancement projects.
• Help reduce downtime through proactive equipment observations and corrective actions.

Continuous Improvement

• Participate in Lean Manufacturing, Six Sigma, SMED, and continuous improvement initiatives to reduce changeover times while maintaining safety, quality, and process stability.
• Use machine data, quality results, scrap trends, downtime information, and production metrics to identify process variation and implement corrective actions.
• Recommend and implement improvements related to safety, quality, productivity, process stability, scrap reduction, and operational performance.
• Identify opportunities to improve setup consistency, machine efficiency, cycle times, and quality performance.
• Document process improvements, troubleshooting findings, and productivity gains as required.

Technical Collaboration & Support

• Serve as a technical resource for operators, production personnel, maintenance technicians, and quality personnel.
• Train and support operators on approved process settings, centerline standards, startup procedures, escalation expectations, and out‑of‑control process conditions.
• Participate in pilot runs, tooling qualifications, process testing, and new product introductions.
• Communicate effectively with Production, Engineering, Maintenance, and Quality regarding process and equipment performance.
• Support cross‑functional projects and assist other departments with technical assignments and training when needed.
• Always be willing to help support other teams with open tasks and projects.

Safety, Quality & Compliance

• Follow all safety procedures and maintain a clean, organized work environment.
• Comply with GMP, Food Safety, and Food Quality requirements as required by the company, customers, and government agencies.
• Attend required safety, technical, and compliance training sessions.
• Support company initiatives related to quality, safety, continuous improvement, and operational excellence.

Qualifications

QUALIFICATIONS (KNOWLEDGE, SKILLS & ABILITIES):

• High School Diploma or GED required.
• Advanced technical certification, apprenticeship, or formal manufacturing education preferred.
• Minimum of 3-5 years of machine setup, processing, maintenance, or technical manufacturing experience preferred.(Blended recommendation based on both source roles.)
• Experience with Blow Molding, Injection Molding, tooling, robotics, and auxiliary equipment preferred.
• Strong understanding of process troubleshooting, process optimization, and root cause analysis techniques.
• Working knowledge of centerlining, OEE, SMED, startup loss reduction, and data‑driven process control preferred.
• Ability to read and understand blueprints, process sheets, wiring diagrams, customer specifications, and technical documentation.
• Ability to work independently and as part of a team with minimal supervision.
• Demonstrated problem‑solving and decision‑making capabilities.
• Basic proficiency with Microsoft Office applications and manufacturing software systems.
• Strong written and verbal communication skills.
• Molder Certification or Master Molder Certification preferred.
• Must maintain flexibility in work hours to support a 24/7 manufacturing operation.
• Must possess personal tools and toolbox appropriate for the position.

PHYSICAL REQUIREMENTS:

• Must be able to stand and walk for long periods of time and lift/carry up to 30 to 50 pounds.
• Must be able to use fingers, hands, and arms for regular tasks.
• Must be able to climb steps, have a good hand‑eye coordination, and bend/squat.
• Must be able to wear proper Personal Protective Equipment.
• Must be able to operate effectively in temperatures ranging from 60 to 110 F.
• Must be capable of visually detecting defects, depth, colors, variances, and see objects.