Machine operators are responsible for a smooth course of machine production. The operator must ensure man, machine and product safety and fulfil all the tasks of his job profile with high accuracy, contributing to a stable course of production and a high level of machine efficiency. Besides "running" the machine, he is able to perform small daily and weekly maintenance, light repair and cleaning works to instructions. To guarantee a high efficiency, a proactive observation upstream and downstream of the machinery is necessary.

General

1. Global process of the machine must have been understood.
2. The method of operation and the technical specifications (e.g. performance data) of the machine/line must have been understood and mastered.
3. The method of operation and the technical specifications of the machine assemblies, related to the job at the machine must have been understood and mastered.
4. At change of shift or start of work, obligation to inform and hand over properly the status of machines, lines and production.
5. Handling and updating of machine relevant documents (spare parts documentation, electrical documents, operating manual).
6. General hygiene regulations must be observed.

Safety

1. Familiarisation with and observation of general and safety regulations, related to the job at the machine (accident prevention regulation)
2. Duty to report serious malfunctions to one's superiors.

Machine operation

1. Operation of the machine (start up, shut down, ...); knowledge in connection with visualisation and control components.
2. Contribution to maintenance cost reduction and OEE (Overall Equipment Effectiveness) optimisation
3. Monitoring of the course of production, analysing of malfunctions and eliminating of slight malfunctions.

Testing/maintenance

1. Installation/removal of wearing parts and performance of minor maintenance work to instruction.   
2. Execution of standard, lubrication (daily and weekly), maintenance, cleaning and service operations according to plan.
3. Carrying out of quality checks as specified. Quality measures with respect to the product must be completed (bottle, product, cap, label, etc. must correspond to quality guidelines (DIN, ABMI, ...)).
4. For all to do´s control of success is necessary.

Set-up/conversion processes.

1. Setting up, replacing and adjusting the formats and machines according to optimum technical and economic considerations, to instructions.

Trouble shooting (Level one)

1. Recognising malfunctions, classifying them correctly and reacting properly (elimination or report).
2. Recognising and interpreting malfunction warnings, alarm signals.

Maintenance personnel is responsible for maintenance and quality assurance for the machines/lines in the area of the beverage, filling and packaging industry. This task comprises the individual machines and connected maintenance groups, pipe systems, … Besides performing the actual maintenance works, the maintenance staff is to be involved in the principle of CIP (continuous improvement process). This means elaboration and implementation of optimisations in the different areas (fault analyses, writing work instructions for changeover and lubrication processes). The standards DIN 31051, DIN EN 13306 (preventive maintenance = maintenance – inspection – corrective maintenance (overhaul – repair) – improvement) act as a basis for the definition of maintenance.

General

1. Global process of the machine/line must have been understood.
2. The method of operation and the technical specifications (e.g. performance data) of the machine/line must have been understood and mastered.
3. The method of operation and the technical specifications of the machine assemblies, related to the job at the machine must have been understood and mastered.
4. At change of shift or start of work, obligation to inform and hand over properly the status of machines, lines and production.
5. Handling and updating of machine relevant documents (spare parts documentation, electrical documents, operating manual).
6. General hygiene regulations must be observed.
7. Proactive process and machine/ line performance optimisation

Safety

1. Familiarisation with and observation of general and safety regulations (accident prevention regulation)
2. Duty to report serious malfunctions to one's superiors.
3. Exceptional safety regulations for servicing must be observed.
4. For all service operations, the legal qualifications must be observed and the operations may only be performed by qualified personnel (electric motors ==> electrician). 

Machine operation

1. Operation of the machine (start up, shut down, ...); knowledge in connection with visualisation and control components.
2. Contribution to maintenance cost reduction and OEE (Overall Equipment Effectiveness) optimisation
3. Performing of functional tests on machines and lines, recognising, analysing and monitoring malfunctions.

Trouble shooting (Level two)

1. Recognising all relevant malfunctions (process - mecanical - electrical), classifying them correctly and reacting properly (elimination or report).
2. Recognising and interpreting all relevant malfunction warnings, alarm signals and visualisations.
3. Restoring the bus systems after replacement of components

Testing/maintenance (preventive - proactive - corrective)/ repair

1. Coordination and performance of machine maintenance works (installation/removal of tear and wear parts and spare parts), considering the principle of SMED (single minutes exchange of dies).
2. Preparation and carrying out of standard, lubrication, maintenance and service operations (possibly according to plan).
3. Setting and checking dimensions, tolerances/back-ups of bus systems essential for functioning.
4. In case of complex operations, it is to be recommended that skilled personnel be requested from the machine manufacturer.
5. specific Documentation of the maintenance measures
6. For all to do´s control of success is necessary.

Set-up/conversion processes

1. Setting up, replacing and adjusting the formats and machines according to optimum technical and economic considerations, to instructions. Control of sucsess afterwork is done.
2. After maintenance work - proof machine line optimisation.