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Key Responsibilities and Required Skills for a Hot End Technician

💰 $65,000 - $95,000+

ManufacturingSkilled TradesEngineering & TechnicalIndustrial Maintenance

🎯 Role Definition

The Hot End Technician is a cornerstone of our manufacturing process, serving as a highly skilled specialist responsible for the heart of production: the forming stage. This individual is the primary owner of the complex, high-temperature machinery—such as Individual Section (IS) machines in glass manufacturing—that transforms molten material into finished products. More than just an operator, the Hot End Technician is a troubleshooter, a mechanic, and a process expert who ensures that this critical equipment runs with optimal safety, efficiency, and precision. Your expertise directly impacts product quality, production volume, and operational profitability, making this a vital, hands-on role for a technically-minded professional who thrives in a dynamic, fast-paced environment.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Industrial Maintenance Mechanic
  • Senior Machine Operator
  • Electromechanical Technician

Advancement To:

  • Hot End Supervisor / Shift Leader
  • Process Engineer
  • Maintenance Manager

Lateral Moves:

  • Cold End Technician
  • Quality Assurance (QA) Engineer
  • Process Improvement Specialist

Core Responsibilities

Primary Functions

  • Take full ownership of the operation, adjustment, and maintenance of high-temperature forming equipment (e.g., IS machines) to consistently produce high-quality products that meet stringent customer specifications.
  • Execute complex and time-sensitive job changes on forming machinery, including the precise setup of molds, neck rings, plungers, and delivery systems, to minimize production downtime and maximize operational readiness.
  • Vigilantly monitor all critical variables of the hot end process, such as furnace forehearth temperatures, gob weight and shape, and machine timing, making real-time adjustments to maintain process stability and control.
  • Perform comprehensive preventative maintenance, scheduled inspections, and lubrication on all hot end machinery, including conveyors, shear mechanisms, and cooling systems, to proactively prevent equipment failures.
  • Expertly troubleshoot and diagnose complex mechanical, electrical, hydraulic, and pneumatic system faults within the forming process, applying root cause analysis to implement effective and lasting repairs.
  • Analyze production data, defect percentages, and quality control feedback to identify negative trends, pinpoint root causes of defects (e.g., checks, blisters, thin walls), and drive process improvement initiatives.
  • Foster a collaborative working relationship with shift supervisors, quality auditors, and cold end personnel to ensure a seamless production flow and unified approach to achieving quality and efficiency targets.
  • Champion and enforce unwavering compliance with all corporate and regulatory safety protocols, including Lock-Out/Tag-Out (LOTO), confined space entry, hot work permits, and the correct use of personal protective equipment (PPE).
  • Act as a subject matter expert to train and mentor junior technicians and machine operators on advanced operational procedures, diagnostic techniques, and critical safety practices.
  • Maintain meticulous and accurate digital records of production activities, machine setting parameters, maintenance work orders, and parts consumption within the Computerized Maintenance Management System (CMMS).
  • Actively participate in and contribute to continuous improvement programs like Kaizen, 5S, and Lean Manufacturing to enhance plant safety, product quality, and overall equipment effectiveness (OEE).
  • Read and interpret highly technical documents, including mechanical blueprints, electrical schematics, and pneumatic/hydraulic diagrams, to facilitate advanced troubleshooting and repair activities.
  • Manage the inventory of critical spare parts, specialized tooling, and essential components for the hot end, initiating procurement requests to prevent stockouts and production delays.
  • Calibrate and fine-tune sophisticated machine control systems, including electronic timers, servo-driven mechanisms, and sensor arrays, to achieve precise, repeatable forming cycles.
  • Meticulously inspect molds, blanks, baffles, and other forming tooling for wear, damage, or defects, coordinating with the mold shop for necessary repairs or replacements to uphold container specifications.
  • Provide immediate and decisive response to machine alarms and process upsets, taking swift corrective action to stabilize the process and minimize the creation of non-conforming products.
  • Support process engineers in conducting trials and experiments for new products, mold designs, or process enhancements by providing hands-on support and invaluable operational feedback.
  • Operate forklifts, overhead cranes, and other material handling equipment to transport and install molds, tooling, and other heavy components in a safe and efficient manner.
  • Monitor and adjust the intricate network of cooling wind systems to ensure proper and uniform cooling of the molds and plunges, a critical factor in preventing thermal defects.
  • Uphold a high standard of housekeeping and organization within the hot end operational area, ensuring the floor is clean, tools are properly stored, and all potential hazards are eliminated.
  • Assist the furnace department by monitoring forehearth temperature profiles and combustion systems, promptly reporting any deviations or anomalies that could impact the forming process.

Secondary Functions

  • Support ad-hoc data requests and exploratory analysis related to machine performance and defect rates.
  • Contribute insights to the plant's long-term capital improvement and technology upgrade strategies.
  • Collaborate with the engineering department to translate persistent operational issues into new design or engineering requirements.
  • Participate actively in daily production meetings, safety committees, and other cross-functional team forums.

Required Skills & Competencies

Hard Skills (Technical)

  • IS Machine Expertise: Advanced knowledge of the operation, repair, and setup of Individual Section (IS) glass forming machines or equivalent hot forming equipment.
  • Multi-Discipline Troubleshooting: Proficient in diagnosing and repairing complex mechanical, electrical, pneumatic, and hydraulic systems.
  • Technical Blueprint & Schematic Reading: Ability to read, interpret, and apply information from complex engineering drawings and schematics.
  • Process Control & Optimization: Strong understanding of process variables and their impact on product quality, with the ability to make data-driven adjustments.
  • Welding and Fabrication: Basic to intermediate skills in welding (MIG, TIG, Stick) and metal fabrication for repairs and modifications.
  • PLC Troubleshooting: Familiarity with troubleshooting and diagnosing issues using Programmable Logic Controller (PLC) interfaces.
  • Precision Measurement: Skilled in using precision measuring instruments like calipers, micrometers, and gauges for quality checks and setup.
  • CMMS Proficiency: Experience using a Computerized Maintenance Management System (e.g., SAP PM, Maximo) for work orders and record-keeping.
  • Servo and Robotics Systems: Knowledge of servo-driven systems and robotics used in modern forming machines.
  • Furnace & Forehearth Dynamics: A solid understanding of how furnace and forehearth conditions affect the molten material and forming process.

Soft Skills

  • Analytical Problem-Solving: A logical and systematic approach to identifying the root cause of problems under pressure.
  • Resilience & Composure: The ability to remain calm, focused, and effective while working in a hot, loud, and fast-paced industrial environment.
  • Attention to Detail: An exceptional eye for detail is critical for identifying subtle changes in machine performance or product quality.
  • Teamwork & Communication: Excellent interpersonal skills to collaborate effectively with diverse teams and clearly communicate technical information.
  • Safety-First Mindset: A deeply ingrained commitment to safety procedures and promoting a safe work culture for oneself and others.
  • Adaptability: Flexibility to work rotating shifts, respond to emergency call-ins, and adapt to changing production priorities.

Education & Experience

Educational Background

Minimum Education:

  • High School Diploma or GED required.

Preferred Education:

  • Associate's Degree or a certificate from a vocational/technical college.

Relevant Fields of Study:

  • Industrial Maintenance Technology
  • Electromechanical Technology
  • Mechanical Engineering Technology
  • Manufacturing Technology

Experience Requirements

Typical Experience Range: 3-7 years of hands-on experience in a similar role within a manufacturing environment.

Preferred: Direct experience as a Hot End Technician or Job Change Technician in a high-volume glass container manufacturing plant is highly desirable. Experience in environments with a strong focus on safety and continuous improvement is a significant plus.

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