Role design and job descriptions for Automotive Plastics Makers: who stops the machine and who decides
Cosmetic faults are a judgement call, and operators watch too many machines. Clear roles stop faults falling between setter, operator, inspector and mould fitter.
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Share your requirementsWhy role design and job descriptions matters in automotive plastics makers
When a bumper comes off with a flow mark, who decides to stop the machine? The operator thinks the setter should decide, the setter thinks the inspector should flag it, and the inspector thinks the operator should have noticed. Meanwhile the machine runs and the bin fills. Without written roles, the answer depends on who is present and how confident they feel.
Clear role design sets who checks what, at what point, and who can stop the machine. The setter owns settings and first-off approval, the operator owns the cycle check and basic cosmetic checks, the inspector owns the standard and the hold decision, and the mould fitter owns tool condition. Each role has a limited list of machines or checks so nobody is stretched past what is workable.
How to set it up
1. Map who touches the part
Follow a moulded part from the press to packing and write every person who handles or checks it. Include the mould fitter and the material handler.
2. Write the stop rule
State who can stop a machine and for what faults. Make it clear that stopping for a real fault is expected, and that the setter must come when called.
3. Set the machine count per operator
Agree a realistic number of machines per operator based on cycle time, part size and checks. Operators watching too many machines miss cosmetic faults.
4. Write one page per role
Cover what the person decides, checks, records and passes on. Use the pages in training and in appraisal. See role design and job descriptions.
5. Post limit samples at the line
Put boundary samples for colour, gloss, flash and sink marks at the line, signed by quality, so the judgement call has a visible reference.
Check these first
Before changing anything, find out what is true today. These take an afternoon and use your own records.
- Count the machines each operator watches on the busiest shift.
- Ask three people who can stop a machine for a cosmetic fault and compare answers.
- Read the last cosmetic complaint and trace who saw the fault first and what they did.
- Check whether limit samples exist for the top five faults on your parts.
GullyHR can do this with you. Read how we approach role design and job descriptions in general, or share your requirements and we will tell you where to start.
Questions owners ask
It depends on cycle time, part size, trimming and checks. Test with the operators on real runs, and reduce the number where faults are escaping. A number set by cost alone usually shows up as scrap.
Inspectors differ, and the customer judges by eye. A signed sample at the line makes the standard the same for everyone and ends arguments about whether a fault is acceptable.
Usually the setter approves the machine settings and the inspector or quality lead confirms the part. Write the rule so there is no gap between the two and the first-off record is kept.