Injection Moulding Setter / Skilled Operator

Reports To:

Production Manager / Shift Team Leader

Job Purpose

To set, operate, maintain, and optimise injection moulding machines and associated equipment to ensure the safe, efficient, and consistent production of high-quality moulded products. The role involves carrying out tool changes, machine set-ups, fault finding, routine maintenance, quality inspections, and ensuring compliance with all company procedures and relevant UK regulations.

Key Responsibilities Machine Setting and Operation

• Set up and operate injection moulding machines to production specifications.
• Perform mould/tool changes safely and efficiently.
• Start-up, shut-down, and monitor production runs.
• Optimise machine settings to achieve maximum productivity and quality.
• Adjust process parameters as required to maintain product conformity.
• Ensure production targets are achieved while minimising waste and downtime.

Tool Changing and Maintenance

• Carry out mould and tool changes in accordance with company procedures.
• Inspect moulds, tools, and associated equipment before and after use.
• Conduct routine servicing and preventative maintenance on moulding machines and ancillary equipment.
• Assist with mould maintenance and minor repairs.
• Ensure all tooling is stored, maintained, and recorded correctly.

Quality Control

• Perform first-off, in-process, and final quality inspections.
• Use measuring equipment including calipers, micrometers, gauges, and other inspection tools.
• Identify and report defects, non-conformances, and quality concerns.
• Maintain accurate production and quality records.
• Support continuous improvement initiatives to improve product quality.

Troubleshooting and Problem Solving

• Diagnose and resolve machine, tooling, and process-related issues.
• Investigate moulding defects such as flash, sink marks, short shots, burn marks, warpage, and contamination.
• Implement corrective actions to minimise downtime.
• Escalate complex technical issues when required.
• Support root cause analysis and corrective action processes.

Health, Safety and Compliance

• Operate all machinery in accordance with Health and Safety regulations.
• Comply with company policies, risk assessments, and safe systems of work.
• Follow Lock Out/Tag Out (LOTO) procedures during maintenance and tool changes.
• Ensure compliance with ISO standards and customer quality requirements where applicable.
• Maintain a clean and organised working environment in accordance with 5S principles.
• Report hazards, accidents, near misses, and unsafe conditions immediately.

Documentation and Reporting

• Complete production documentation accurately and on time.
• Record machine settings, downtime, maintenance activities, and quality checks.
• Support production planning and shift handovers through effective communication.
• Participate in audits and compliance inspections as required.

Skills and Experience Essential

• Proven experience as an Injection Moulding Setter or Skilled Operator.
• Strong understanding of injection moulding processes and machine operation.
• Experience carrying out mould/tool changes.
• Knowledge of process optimisation and troubleshooting techniques.
• Ability to read technical drawings and manufacturing documentation.
• Experience using measuring and inspection equipment.
• Good understanding of Health & Safety requirements within a manufacturing environment.
• Strong problem-solving skills and attention to detail.
• Good communication and teamwork skills.

Desirable

• Experience with robotic handling systems and ancillary equipment.
• Knowledge of scientific moulding principles.
• Experience working within ISO 9001, 14001 and 45001 environments.
• Forklift Licence.
• Overhead Crane or Slinging and Lifting certification.
• Mechanical or engineering qualification (NVQ Level 3 or equivalent).

Personal Attributes

• Reliable and self-motivated.
• Strong attention to detail.
• Flexible and willing to work shifts when required.
• Positive attitude towards continuous improvement.
• Able to work independently and as part of a team.
• Commitment to safety, quality, and operational excellence.

Key Performance Indicators (KPIs)

• Production efficiency and output.
• Machine uptime and utilisation.
• Scrap and waste reduction.
• Quality performance and defect rates.
• Tool change completion times.
• Compliance with safety and quality procedures.
• Housekeeping and audit performance.

Working Conditions

• Manufacturing and production environment.
• Regular lifting and handling of moulds and equipment in accordance with safe working practices.
• PPE required at all times.
• Shift work and overtime may be required to meet business demands.

Salary

Competitive salary dependent on skills, experience, and qualifications. Overtime and shift to be agreed, Company Pension and GBS bonus scheme.