OBJECTIVE OF THE POSITION: Production Associates will operate all equipment and produce all finished products to comply with all laws, policies and standards governing food safety and quality. Production Associates are obligated to report all food safety and quality issues that may occur.

SUMMARY: Must be able to work in a “Team Environment”. Responsible for inspecting product for uniformity and quality prior to packaging. For breaking down stacks of empty trays to be sorted by color, bakery names (stamped on trays) and sorting out trays that have been broken from use. Responsible for feeding trays into a tray washer and pulling stacked product out of stacking machines to be placed into product staging lanes. Also, setting and pulling metal pans from production line at start-up, shutdown, and product changeovers. Other responsibilities including making sure product codes on packages are legible. Discarding scrap dough and buns into compactor and keeping work area clean and orderly. And any other duties assigned by supervision. Duties are rotated as instructed by supervision. Attend regularly and on time a five- or six-day workweek including weekends, holidays, and possible split days off. Schedule 8 hours or more per day.

RESPONSIBILITIES:

• Inspection of product for uniformity and quality prior to packaging
• Sorting Trays – by color, other suppliers, broken.
• Feeding trays to tray washer
• Operating Pan Stacker/Un-stacker as needed.
• Aiding in product changeovers
• Discarding scrap / waste disposal / mopping excess water
• Must maintain an organized, clean and sanitary working area.
• Communicating with others. i.e. operators, utility personnel, supervisors
  1. Pre-Wrap Product Inspection: Requires bending, lifting and stretching over 4’ conveyor. (Hands must be clean, sanitary and in gloves!)
     1. Stand at inspection station and wrapping machines and using both hands, remove inferior product that does not meet KBI standards.
     2. Placing inferior product into waste containers to be weighed for a cripple/damaged count.
     3. Responsible for reporting quality issues and machine problems to supervision or wrapping operator immediately.
     4. Using both hands, keeping product lanes even for smooth operation of wrapping machine and keeping product lanes free of “bun jams”.
     5. Know how to switch “split product conveyor” between east and west wrappers.
     6. Know how to operate all switches and buttons on inspecting station control panel: assist button, master stop button, accumulator speed dial, in feed speed dial, manual/automatic switch bun grouper section and north/south slicer on buttons.
     7. Be able to react quickly if wrapping machine quits running and know what actions to take.
     8. Know how to safely un-jam wrapper at basket loader.
     9. Keep area clean and orderly and know where to find cleaning supplies. Remember to wear safety goggles when using compressed air.
  2. Tray washer: Overhead stretching, stooping, bending, and thrusting required.
     1. Be able to safely break down stacks of empty trays up to 7’8” high.
     2. Sort trays by color, bakery name (stamped on trays) and sort out broken trays.
     3. Know what color tray to load into washer for the product to be ran (ask loaders).
     4. Know where broken trays are placed at tray washer and where to take broken trays at end of the shift.
     5. Know where to store trays getting returned to the bakery that are heavily soiled. These trays need to be removed from the tray washer line and set aside for Sanitation.
     6. Using tray washer start button, load trays into tray washer properly and keep conveyor line full of trays.
     7. Occasionally, empty trays coming back from stores will have items that need to be returned to McDonalds. Know where to place these items.
     8. Know where assist button is located to notify wrapper operator of any problems.
     9. Carefully and safely be able to un-jam tray kick-plates that feed the east and west bun wrappers with empty trays.
     10. If both wrappers go down or quit running, know how to catch product properly at product run-off area.
     11. Emergency stop button locations.
     12. Learn “Tray washer Control Panel.”
     13. Keep tray washer tank skimmed of dirt, etc. to ensure proper tray cleanliness. Caution: tray washer water is between 160-175 degrees!!
     14. Know how to drain, clean, and fill tray washer tank.
     15. Keep area clean and orderly.
  3. Wrapped Product Inspection: Requires bending, lifting, stooping and stretching.
     1. Visually inspect full trays of wrapped product for quality, correct bun count, and legible code printed on top of each package. And frequently pulling full trays off of line and checking packages for a good seal.
     2. Must know and understand the codes that are printed on packages.
     3. Assist in running off product if wrappers stop running.
     4. Know how to “Re-Wrap” product that does not meet KBI quality standards by using plastic tray sheets to flip packages over and repair from the bottom of package.
     5. Be able to “Stack-Off” full trays if stackers go down or stop running.
  4. Pan Pulling and Setting: Requires lifting, pulling, pushing, and twisting. Proper lifting techniques a must to prevent injuries to back!!
     1. Be able to safely pull pans offline and stack gently to a safe height.
     2. Know how to place pans properly and gently onto line for dough placement and at what distance to space pans for smooth and safe operation.
     3. Learn where to retrieve gloves, hot pads, and arm protectors for handling pans.
     4. Pull stuck buns out of pans to be stacked and where to discard stuck buns. (Stuck buns left in pans reduce the life of the durashield coating on pans.)
  5. Pan Stacker/Unstacker:
     1. Be able to read, understand and operate control panels for each machine.
     2. Know how to safely remove pan jams in stacker, unstacker and pan line.
     3. Know how to properly stage pan carts by variety.
     4. Must know where all reflectors and photo-eyes are located on the stacker, unstacker and pan line. All reflectors and photo-eyes shall be always clean.
     5. Area must be clean and always organized.

1. Other Duties:
   1. Disposing of scrap buns or dough in compactors and the safe way to operate.
   2. Know where and how to record scrap buns/dough that is thrown into compactor.
   3. Assist the Production Supervisor in keeping all product toppings full in the seeder area, if necessary.
   4. Occasionally helps Wrapping Operators conduct blade changes.
   5. Mopping of bakery floor and where to get cleaning supplies.
   6. Cleaning machinery framework, conveyors etc.
   7. Remember to always check the S.D.S. manual before using any chemicals.

GENERAL:

1. Logic and Reasoning Ability:
   • Able to solve problems relating to quality requirements and testing.
2. Math Ability:
   • Able to add subtract, multiply, divide, and estimate.
3. Integrity:
   • Honest, respectful of others, calm and patient in the face of adversity.
4. Physical:
   • Capable of standing and walking for long periods of time. Capable of exerting up to 40 lbs. of force frequently and pushing 200 lbs. of stacked product across floor. Must be able to reach above 7’8” to stacked product.
   • Capable of climbing, standing for long periods, walking, grasping, lifting, stacking, pushing, and pulling.
   • Must be capable of mental and visual ability to be able to inspect codes and packages and to count product. Must possess basic calculations of counting, addition, multiplication and division.
   • Capable of understanding and reading work schedules, plant signs/notices, safety regulations postings on bulletin boards or SDS sheets found in the SDS binder.
   • Worker subject to both inside and outside environmental conditions and temperatures above 100 degrees that is process related and more extreme in summer months. Workers subject to outside temperatures below freezing.
   • Workers subject to occasional noise sufficient to cause the worker to shout in order to be heard.
   • Worker subject to hazards such as proximity to moving parts, electrical current and moving objects carrying significant weight and force.
5. Environmental:
   • Work within a noisy environment.
   • Work within a non-climate-controlled workspace where temperatures may vary (typical in manufacturing environments).
6. Dependability:
   • Good attendance

SAFETY:

7. Adhere to OSHA policies and company safety procedures and requirements.
8. Submit documentation for safety hazards to a supervisor when identified.
9. Avoid rushing, awkward positions, and lifting heavy objects alone.
10. Be “accident-free”.
11. Be LOTO trained and understand LOTO procedures.

FOOD SAFETY:

12. Understanding of HACCP.
13. Follow all GMPs.
14. Properly follow allergen procedures
15. Monitor product surfaces and work area for any source of cross contamination.
16. Report any foreign material or food safety risk to a supervisor immediately.
17. Lead by example by demonstrating what is expected of the food safety culture of Klosterman Baking Company.
18. Assist in distributing food safety culture surveys to employees.