Foam Manufacturing Specialist

4 weeks ago

Deer Park, Victoria, Australia Dunlop Foams Full time
About Us

Dunlop Foams is a leading manufacturer of industrial and consumer foams, operating across seven factories nationally in Australia and New Zealand.

We are part of The Comfort Group, Australasia's largest bedding and foam manufacturer, and our products are used for diverse needs, including bedding, furniture, healthcare, sports, packaging, transport, cleaning, and custom-made to order.

The Opportunity

We are seeking a Foam Specialist to provide specialist foam-making expertise and technical support to evaluate existing processes and design and implement new processes to produce industrial polyurethane foams while reducing costs and improving sustainability.

The successful candidate will be responsible for:

  • Programming, designing, and implementing complex automation solutions for electronic control systems used in industrial applications.
  • Providing oversight, training, and advice to the manufacturing team on the correct procedures for specialist operation of the foam-making plant equipment instrumentation and control systems.
  • Adjusting foam-making plant equipment instrumentation and control systems settings, liaising with engineering for the repair or replacement of worn or defective parts as required to maintain machinery and ensuring the instrumentation is operating within fine-tuned parameters.
  • Ensuring the blending of chemical ingredients for specific products is recorded and incorporated into formulations which are programmed into foam-making plant equipment instrumentation and control systems.
  • Monitoring, recording, and reporting on emissions and/or exposure for toluene diisocyanate and dichloromethane in line with government and business requirements.
  • Monitoring production variables and attributes for the analysis of statistical quality control.
  • Demonstrating the use of statistical quality control data by ensuring programmed operational processes for the foam plant equipment instrumentation and control systems have repeatable and reproducible methods and products.
  • Using Six Sigma methodologies by measuring production parameters and ensuring variables are within their tolerance.
  • Developing speciality foam manufacturing specifications, and determining appropriate formula modifications including chemical flow volumes taking into consideration machine capacity and operating parameters.
  • Ensuring any new or modified speciality foam manufacturing specifications are documented, and where appropriate foam plant equipment instrumentation and control systems are programmed with modified designs and operation controls to maximise yield and reduce waste.
  • Leading improvement projects related to machine performance, reliability, safety, and design.
  • Performing technical pre-start checks of foam plant equipment instrumentation and control systems to ensure they are operating within specified parameters.
  • Undertaking fault finding and issue diagnosis of foam plant equipment instrumentation and control systems as part of routine maintenance requirements.
  • Responsible for ensuring appropriate maintenance schedules are in place and both routine maintenance and breakdown repairs to foam plant machinery are performed in line with engineering principles.
  • Recording operation and yield information and analysing to provide output statistics for the Operations Manager.
  • Safety and Quality Management System accountabilities and responsibilities relevant to the position as outlined in the Safety &/or QMS system guidelines and procedures.
About You

The successful candidate will be a Foam Specialist who has experience in a similar position and can demonstrate the following skills and attributes:

  • Tertiary qualification in manufacturing, information systems, or engineering is preferred.
  • Advanced business, system, and process analysis skills, able to identify, document, and re-engineer critical business processes and systems to achieve desired outcomes.
  • 5+ years' experience programming, designing, and implementing complex automation solutions for electronic control systems used in industrial applications.
  • Working knowledge of chemical safety management and appropriate handling mechanisms.
  • A good understanding of structured methodologies including TOC, LEAN, 5S, etc.
  • Intermediate to advanced production control systems & computer user including the ability to develop reports and perform statistical analysis.
  • Knowledge of HASE Act and how to apply this in a manufacturing environment.
  • Strong understanding of manufacturing and production environments, including a proven track record of success in a high volume, short lead time, or mass customisation environment.
  • Must be familiar with all operations of the plant instrumentation and controls for the foam conversion and CNC automated cutting lines and ensuring compliance with agreed set-up, operation, and maintenance.
  • Demonstrate and maintain a high standard of personal conduct to ensure compliance with all legislative and/or Company policy obligations.
  • Good mechanical understanding of running, troubleshooting, and maintaining automated plant machinery including electronics and control systems.
  • Demonstrate a high level of initiative with a proactive approach to management.
  • Strong relationship building and leadership skills with the ability to influence and motivate others.
On Offer

Joining Dunlop Foams means becoming part of a passionate team committed to innovation and opportunity, as well as:

  • Opportunities for professional development and career growth.
  • Competitive salary and staff benefits.

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