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Quality Technician - Night Shift 8 PM - 6 AM - (4 Crew, 10 Hours 7 Day (2-2, 3-2, 2-3) 2 Week Cycle) in Henderson, KY at Koch Enterprises, Inc.

Date Posted: 1/19/2019

Job Snapshot

Job Description


Gibbs Die Casting is an Equal Employment Opportunity Employer and as such will recruit, hire, train, and promote persons in all job titles without regard to race, color, religion, national origin, sex, age, sexual orientation, veteran status, genetics, physical or mental disability, or other protected characteristic.

TITLE: Technician                                                      PLANT: Federal                                            

DEPARTMENT: Quality                                             REPORTS TO:  Lead or Supervisor or Quality Manager          

FLSA STATUS: Hourly/Non-exempt                         PAY GRADE: Level dependent 13-18




To ensure customers receive a quality die cast product by ensuring quality checks and required documentation are complete and accurate.  Safely perform all tasks required to meet all safety and production goals while maintaining a 7S system, participating in continuous improvement and supporting team members.



The following list includes the type and scope of work as a part of this job.  In compliance with the Americans with Disabilities Act, Gibbs Die Casting Corporation provides reasonable accommodations to qualified individuals with disabilities and encourages both prospective and current Team Members to discuss potential accommodations with the Human Resources Department. Team members are responsible for personal development and progression of skill levels through Level 4 of their home department. Level 5 candidates will be selected by management.  Team members are required to become proficient (Level 3) at minimum in two other departments.

Level 5 – Team Lead Trainer

  • Quality Engineer in training.
  • Subject matter expert in all aspects.
  • Model of Gibbs ideal Team Member.
  • Completed all internal level and external training.
  • Lead continuous improvement teams and activities.
  • Train and monitor training activities.
  • Lead production activities required to meet production goals.

Level 4 – Self Directed/Subject Matter Expert

  • Level 5 candidate.
  • Performs job autonomously (Operator preventative maintenance, production processes, setups, minor repairs, cleaning, production troubleshooting, resolve quality issues).
  • Complete all previous internal level and external training requirements.
  • Exhibits Gibbs team member values.

•        Takes an active role in assisting the Plant and Production Manager in coordinating the activities of the Plant Quality Control function.

•        Regularly reviews statistical data in the plant to ensure Cpk values are maintained and current for inclusion on test certificates and quarterly reports, per customer requirements.

•        Assists in Plant Quality Control paperwork requirements as necessary for preparation of Quality Control documentation, FMEA preparation, etc.

•        Main contact person for quality decisions generated from Quality Control and production floor. 

•        Be able to assist in troubleshooting measurement problems and seek assistance from the gage engineer to resolve the problem.

•        Monitors, reacts, and updates information and documentation related to all process changes, quality documentation, deviations, TANs, and print revision updates on a daily basis.

•        Aids in the transition of PPAP approved parts from layout to QC; ensuring the proper equipment is accessible, documentation is up to date, and trains levels 1, 2 and 3. 

•        Manage and control the registration, storage, and distribution of all process related documents, which include updating document database list and obtaining proper approvals on a daily basis. 

•        Enters SPC data (e.g. - in-process critical dimensions, sediment testing, hardness, etc.) into SQC pack from in-process sheets for trends, out of control conditions and accuracy on a daily basis.

•        Champions containment activities for all external concerns.

•        Performs periodic layered audits.

•        Posts applicable communication and graphs in plant.

  • Train or monitor training activities.

Level 3 - Proficient

  • Level 4 candidate.
  • Quality contact person on the production floor.

•        Assist in development of new programs to insure that we meet internal and external customer needs. (Includes team involvement with control plans, PFMEAs, process flow diagrams, inspection standards, capability analysis, gages, mistake proofing, etc.).

  • Create / update quality documentation and train team members accordingly as required for corrective and preventative actions, deviations, temporary alert notices, gauging methods, online work instructions and rework instructions. 
  • Make solid data & fact driven quality decisions. Assist and teach others in the quality decision-making activities, customer requirements, gage techniques, inspection and part fit and function features detrimental to customer satisfaction.
  • Actively involved in cross functional problem solving teams to perform root cause analysis for failures internally and those affecting our customers thru defect recreation, is/in not, 5 why & cause & effect.
  • Manage & disposition suspect product to ultimately achieve a “no hold area”.
  • Champion and coordinate manpower for containment activities including setting up 3rd party sorts within the plant.
  • Audit lines in each area, final inspection and off-line inspection for compliance of quality standards & documentation.
  • Raises the flag to stop production when critical non-conforming work habits and/or product put the customer at risk.  This includes process verifications not performed (error proofing rabbits), no standard work, operators not trained and not following quality operating standards.
  • Ensures that routing tags/labels and any required customer tags are properly attached to baskets/skids and all information is correct.
  • Lead teams in continuous improvement activities on the shop floor.
  • Perform other duties as assigned by the Quality Manager / Engineer.
  • Actively pursue training towards Level 4 completion within one year of reaching Level 3
  • Train as requested.

Level 2 – Functional

  • Level 3 candidate.
  • Follows all aspects of Safety as described in Gibbs Safety Roles and Expectations.
  • Performs Dimensional and Visual inspection checks of on-going production according to the Manufacturing plan.
  • Executes the standard reaction program when defective or out-of-specification parts are found, including documentation of corrective action.
  • Maintains good and controlled material flow by:

o   Prompt application of hold tags whenever suspect material is identified.

o   Completing of non-conforming Material Reports to document suspect material disposition.

•        Performs quality verification of all reworked material.

•        Supports the department mandate to participate and assist in Root Cause Analysis whenever problems arise.

       Level 1 – Entry

  • Level 2 candidate.
  • Actively pursue training towards Level 2 completion within six months of reaching Level 1.
  • Able to work weekends and overtime as required.
  • Follow all aspects of Safety as described in GDC Safety Roles and Expectations.
  • Follows all prescribed safety regulations including the proper use of all required personal protective equipment.
  • Maintains the work area and equipment in a clean and orderly condition according to established Gibbs 7-S Guidelines.
  • Performs any activities or training requested by Management.



To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Education: High School diploma or GED required.  Associate's degree or higher is preferred.

Experience: Manufacturing, preferably in quality, familiar with control plans, inspection standards, customer blueprints and measurement tools. Knowledge of the following is not required but preferred: Blue print reading, GDT, Measurement tools, SPC, general problem solving, ISO or IATF1649 audit training.

Communication:  Ability to read, analyze, and interpret data, engineering standards, blueprints, and procedure & manuals.  Ability to effectively present information and respond to questions from groups of managers, clients, customers, and the public. Good verbal and written communications skills with ability to communicate specifications and requirements clearly in written and drawing formats.

Mathematics:  Ability to apply concepts such as fractions, percentages, ratios, and proportions to practical situations. Prefer having the ability to work with mathematical concepts such as probability and statistical inference, and fundamentals of plane and solid geometry and trigonometry. 

Reasoning and Problem Solving:  Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exists.  Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form.

Computer Skills:  Basic web based or MS Access data entry, Microsoft Excel, SPC software is a plus.

Other Requirements:  Ability to define problems, collect data, establish facts, and draw valid conclusions.  Ability to perform duties under minimal supervision while exercising discretion and sound judgment. Demonstrate a professional demeanor and be team player.

Travel:                        ___X_10% or less                 ____11%-50%                         ____51% or more


Management has the right to revise this description at any time. The job description is not a
contract for employment, and either you or the employer may terminate employment at any time, for any reason as outlined in the employee manual or other written agreement. 

EEO m/f/d/v  Other details
  • Job Family PROD
  • Pay Type Hourly
  • Employment Indicator Regular
  • Travel Required Yes
  • Travel % 10
  • Required Education High School