Machine Operator III

Machine Operator III

The Machine Operator III is responsible for the safe and efficient manufacturing, movement, storage, staging, and tracking of raw materials, work-in-process (WIP), and finished goods throughout the polyurethane foam fabrication facility. This role requires advanced knowledge of foam fabrication materials, equipment operation, inventory management systems, and department workflows. The Machine Operator III may serve as a lead worker, providing guidance to other employees.

Material Movement & Staging

Receive, inspect, and verify incoming raw materials including polyol, isocyanate, additives, and laminate stock against purchase orders and delivery documents.

Stage raw materials and components at designated production areas according to production schedules and batch sheets.

Transfer finished foam buns, cut parts, and fabricated components between production, storage, and shipping areas using forklifts, pallet jacks, and hand trucks.

Operate overhead hoists and material lifts to move large-format foam blocks as required.

Ensure proper sequencing and rotation of raw material inventory (FIFO) to prevent waste and material degradation.

Inventory & Documentation

Perform cycle counts and physical inventory audits; reconcile discrepancies with inventory records.

Maintain accurate records in the warehouse management system (WMS) and/or ERP system for material receipts, transfers, and consumption.

Apply correct labels, lot numbers, and identification tags to all materials and finished goods.

Track and report chemical drum and tote usage, ensuring proper documentation for hazardous materials compliance.

Coordinate with production and quality teams to manage non-conforming materials and facilitate disposition.

Equipment Operation

Operate sit-down and stand-up counterbalance forklifts, reach trucks, and electric pallet jacks safely and in compliance with company standards.

Conduct pre-shift equipment inspections and report defects or maintenance needs promptly.

Operate foam bun conveyors, powered roller systems, and material handling attachments as required.

Chemical & Hazardous Materials Handling

Handle, transfer, and store polyurethane chemical components (polyol, MDI/TDI isocyanates, blowing agents, catalysts) in accordance with SDS guidelines and regulatory requirements.

Monitor chemical storage areas for temperature compliance, container integrity, and proper segregation.

Assist with drum and tote transfers, including pumping and weighing operations.

Ensure chemical waste and empty containers are managed per RCRA and facility environmental policies.

Safety & Housekeeping

Maintain work areas in clean, organized, and hazard-free condition; enforce 5S standards.

Adhere to all personal protective equipment (PPE) requirements including gloves, safety glasses, steel-toed footwear, and respiratory protection where applicable.

Identify and report unsafe conditions, near-misses, and incidents immediately to supervision.

Participate in safety observations, toolbox talks, and required training programs.

Lead & Training Support

Provide on-the-job guidance and informal training to Material Handler 1 and 2 employees.

Assist supervisor with workflow coordination and task assignment during peak production periods.

Serve as backup in the absence of the Material Handler Lead or Supervisor as directed.

Requirements

Education

High school diploma or GED equivalent required.

Experience

Minimum 35 years of machine operating experience in a manufacturing or industrial environment required.

Prior experience in foam, chemical, or plastics manufacturing strongly preferred.

Experience operating forklifts and powered industrial trucks required.

Licenses & Certifications

Current forklift operator certification (sit-down counterbalance and reach truck) required or ability to obtain within 30 days of hire.

Hazardous materials handling certification preferred (HAZWOPER awareness-level or equivalent).

Knowledge, Skills & Abilities

Solid understanding of polyurethane foam raw materials, chemical properties, and safe handling requirements.

Proficiency with WMS, ERP, or inventory management software; basic computer skills required.

Ability to read and interpret work orders, bills of lading, SDS sheets, and production schedules.

Strong attention to detail and commitment to accuracy in documentation and inventory management.

Demonstrated ability to work effectively in a fast-paced, team-oriented environment.

Basic math skills including weights, measures, and quantity calculations.

Physical Requirements

Frequent standing, walking, bending, and reaching throughout the shift.

Regular lifting and carrying of materials up to 75 lbs.

Operating powered industrial trucks.

Exposure to chemical fumes/dust.

Working in hot/cold temperature extremes.

Must remain alert and physically active in a fast-paced production environment.