Mold Repair Operator

Mold Repair Operator

Martinsburg, West Virginia | Onsite

BUSINESS UNIT

AKER by MAAX / American Bath Group

DEPARTMENT

Mold Repair / Mold Maintenance / Production Support

REPORTS TO

Mold Maintenance Supervisor or Lead

CLASSIFICATION

Hourly, non-exempt

SCHEDULE

5:00 a.m.-3:30 p.m.; Friday overtime as needed, generally communicated by Wednesday.

Position Summary

Restore damaged or worn production molds to an approved, safe, dimensionally controlled, and production-ready condition. Assess defects, plan and complete authorized fiberglass or composite repairs, rebuild damaged areas, restore tooling surfaces, verify cure and finish quality, document repair history, and route molds for release or additional technical review.

Where the Role Fits in the Manufacturing Process

Mold Repair is a skilled production-support function that receives molds removed from service, placed on hold, or identified through inspection. Molds define bathware shape, dimensions, and surface appearance; damage can transfer to finished units, increase rework and scrap, interfere with release, or stop production. The role focuses on damage diagnosis, controlled repair, structure and surface restoration, and formal return-to-service review. Routine cleaning, waxing, preventive maintenance, and hanger changes support repair work when assigned but are not the primary purpose of the position.

Essential Duties and Responsibilities

• Review open repair orders, production priorities, molds on hold, carryover work, cure status, replacement-mold availability, and the prior-shift handoff. Prioritize work by production need, safety risk, defect severity, and cure requirements.
• Receive and inspect molds removed from production for cracks, chips, pits, scratches, porosity, delamination, edge or flange damage, worn surfaces, release problems, distortion, or other reported conditions.
• Verify mold number, revision, product family, repair location, production status, repair request, hold condition, production need date, and authorization level before moving a mold or beginning work.
• Clean the affected area and use approved lighting, measuring tools, templates, or reference points to assess the visible extent and likely cause of damage. Document defects and identify whether the work involves surface, backing, edge, flange, or dimensional concerns.
• Classify repairs under approved plant limits. Escalate structural, dimensional, design-sensitive, recurrent, or safety-critical damage before proceeding; do not treat those conditions as cosmetic work.
• Prepare repair areas through controlled grinding, sanding, routing, cutting, beveling, cleaning, drying, masking, and removal of damaged material without extending damage into sound mold structure.
• Stage and use only approved materials, tools, mixing equipment, templates, and waste controls. Measure, mix, and apply resin, reinforcement, filler, tooling gel coat, surface materials, catalysts, and hardeners according to work instructions and safety data sheets.
• Rebuild damaged backing, edges, flanges, corners, radii, inserts, or production surfaces within the approved repair scope. Protect unaffected tooling surfaces, reference features, vacuum or air passages, mounting points, and controlled geometry.
• Control laminate orientation, layer count, thickness, contour, material ratios, working time, temperature, humidity, and cure time as required by the repair standard.
• After the specified cure period, shape, sand, blend, polish, and finish repaired areas so contour, radius, flatness, surface profile, gloss, texture, transitions, edge condition, and release condition meet acceptance criteria.
• Inspect completed repairs for cracks, voids, pinholes, porosity, soft cure, incomplete bonding, delamination, print-through, exposed reinforcement, contour mismatch, sharp edges, contamination, trapped air, or other conditions that could transfer to product.
• Apply approved wax or mold-release preparation after repair when assigned and qualified. Follow required coat counts, coverage, timing, buffing methods, and release procedures.
• Maintain tags, segregation, and hold status until the mold is safe, fully cured, dimensionally acceptable, properly finished, documented, and approved for return to production. Obtain the required supervisor, Quality, Engineering, or tooling approval.
• Maintain repair records identifying the mold, revision, defect, repair classification, materials or batch information when required, work performed, cure status, inspection result, disposition, and approval.
• Report recurring damage and suspected causes involving handling, demolding, hanger or fixture condition, process settings, mold design, and storage practices. Communicate delays related to damage, cure, materials, or approval requirements promptly.
• Use repair materials and consumables within approved quantities, shelf-life limits, storage conditions, and batch controls. Maintain accurate backlog, hold, cure, approval, and completion information for production planning.
• Maintain clean tools, controlled materials, ventilation, waste containers, emergency access, and a contamination-controlled repair area. Complete records, communicate mold status and unresolved conditions, and provide a clear shift handoff.

Quality Expectations

• Verify mold identity, revision, orientation, production surface, repair location, and approved repair classification before removing or applying material.
• Follow approved mix ratios, lot controls, reinforcement schedules, thickness requirements, cure conditions, sanding and polishing sequences, and release preparation.
• Restore controlled contour, radius, flatness, surface profile, gloss, texture, and edge condition without high or low spots, print-through, visible transitions, or damage to unaffected features.
• Inspect for surface, laminate, bond, cure, and dimensional defects; do not shorten cure time, conceal defects, bypass approvals, or release incomplete work to meet production pressure.
• Keep the mold on hold until all cure, dimensional, surface, documentation, and release criteria are satisfied. Maintain repair history that supports tracing repeat conditions to the mold, production area, handling practice, or process.

Tools, Equipment, and Materials

• Fiberglass or composite production molds, frames, carriers, repair stands, cradles, carts, and approved lifting or positioning devices.
• Orbital or dual-action sanders, grinders, rotary tools, drills, polishers, buffers, routers, scrapers, files, shears, knives, and other approved hand or powered tools.
• Task lighting, inspection mirrors, straightedges, radius and profile gauges, templates, calipers, rulers, thickness tools, and approved hardness or cure-check devices.
• Local exhaust, downdraft or portable dust collection, grounded or approved vacuum equipment, mixing stations, spill supplies, and hazardous-waste containers.
• Approved resin systems, fiberglass mat or cloth, reinforcement, fillers, tooling gel coat or other mold-surface materials, catalysts or hardeners, pigments, release films, and repair consumables.
• Approved cleaners, solvents, lint-free cloths, abrasives, polishing compounds, finish wax, release and masking materials, mixing cups, scales, timers, and application tools.
• Repair travelers, hold tags, mold-history records, drawings, specifications, work instructions, electronic maintenance systems, and material-lot records.

Authorization: Complete only repair classes, chemical processes, powered-tool work, lifting operations, dimensional corrections, and release steps covered by documented training and authorization. Major structural rebuilds, design changes, insert replacement, welding, electrical work, uncontrolled heating, and engineering changes remain outside the role unless specifically assigned and qualified.

Safety and Personal Protective Equipment

• Follow hazard-communication requirements, safety data sheets, chemical labeling and storage rules, written repair procedures, and task-specific training.
• Use approved ventilation and dust controls during grinding, sanding, routing, cutting, mixing, application, curing, cleaning, polishing, and buffing.
• Control ignition sources and follow site requirements for flammable or combustible materials, resins, solvents, catalysts, hardeners, and contaminated waste. Separate chemicals according to compatibility and storage rules.
• Inspect tools, cords, guards, abrasives, hoses, vacuums, ventilation, carts, stands, hoists, and lifting devices before use. Remove defective equipment from service.
• Use approved lifting, positioning, blocking, and support methods for large or awkward molds. Never work beneath an unsecured or suspended load or place the body in a pinch-point path.
• Apply lockout/tagout or other energy-control steps only when required and within documented authorization.
• Keep eyewash stations, safety showers, fire equipment, exits, electrical panels, ventilation inlets, and access aisles unobstructed. Follow current site emergency and incident-reporting procedures.
• Immediately report spills, splashes, exposure symptoms, unusual odors, ventilation failures, uncontrolled heat, smoking or overheating material, tool damage, near misses, and injuries.

Use the PPE selected through the site task-specific hazard assessment, exposure monitoring, equipment instructions, chemical inventory, safety data sheets, and written Environmental, Health and Safety (EHS) programs.

Condition / Task

Required Protection

General repair-area work

Safety glasses with side protection; safety-toe, slip-resistant footwear; plant-approved clothing; task-appropriate gloves.

Grinding, sanding, routing, or cutting

Eye protection; face protection when required; hearing protection; cut- or abrasion-resistant gloves; EHS-selected respiratory and protective-clothing controls.

Resin, catalyst, hardener, coating, or solvent handling

Chemical-resistant gloves selected for the substance; splash goggles and/or face shield; protective garments; respiratory protection when required by the hazard assessment.

Polishing or buffing

Eye protection; hearing protection when required; suitable gloves; controlled clothing; required respiratory protection for hazardous dust or vapor.

Mold movement or lifting work

Safety footwear and handling gloves; head or high-visibility protection where required by traffic, overhead, or lifting hazards.

Noise-designated areas

Hearing protection as posted or required by the hearing-conservation program.

Respiratory protection: Required respirators are managed through the site written program, including medical evaluation, fit testing, cartridge or filter selection, change schedules, training, inspection, maintenance, and proper use.

Physical Demands

The work requires the following physical activities. Reasonable accommodations will be considered in accordance with applicable law.

Activity

Frequency

Work Application

Standing

Frequent to constant

Repair preparation, material application, sanding, finishing, and inspection.

Walking

Occasional to frequent

Moving among repair bays, molds, tools, materials, and records.

Sitting

Occasional

Bench work, detailed repair, documentation, or controlled cure periods.

Stooping, kneeling, and squatting

Frequent

Accessing lower surfaces, backing, flanges, and repair stands.

Repetitive hand use

Frequent to constant

Sanding, grinding, mixing, laminating, polishing, and wiping.

Simple and power grasp

Frequent

Controlling tools, handling materials, and positioning equipment.

Fine manipulation

Frequent

Mixing, detailed surface work, filling, inspection, and records.

Overhead or extended reach

Occasional

Accessing tall, curved, or elevated mold areas.

Vision and coordination

Frequent to constant

Detecting small defects, matching contour and finish, and controlling powered tools.

Lift, carry, push, pull, and position molds, carts, tools, materials, and fixtures within established handling limits using approved supports, lifting aids, and team assistance. Detailed repair and inspection require visual acuity, depth perception, color recognition, and focus adjustment sufficient to assess defects and restore contour and finish.

Work Environment

• Indoor manufacturing and repair work near production lines, stored molds, repair stands, moving equipment, carts, and material-handling traffic.
• Potential exposure to fiberglass fibers and dust, sanding or grinding particulate, resin or coating vapors, styrene or other process odors, fillers, pigments, waxes, cleaners, solvents, catalysts, hardeners, and contaminated waste.
• Noise from powered tools, ventilation, dust collection, production equipment, and material handling that may require hearing protection.
• Seasonal temperature and humidity variation in a non-climate-controlled area, affecting employee comfort, material working time, cure, and repair quality.
• Contact with sharp edges, rough fiberglass, rotating tools, pinch points, cords, hoses, wet materials, tacky surfaces, and elevated or awkward mold geometry.
• Close visual inspection under task lighting and sustained repetitive hand activity during preparation, repair, sanding, polishing, and finishing.

Qualifications and Capabilities

• High school diploma, GED, or comparable education.
• Read and follow repair procedures, work instructions, safety data sheets, drawings, mold records, quality standards, and material instructions.
• Accurately identify mold numbers, revisions, repair locations, hold status, material requirements, cure status, and required approvals.
• Demonstrate mechanical aptitude and controlled use of assigned hand and powered tools for cutting, grinding, sanding, shaping, drilling, polishing, and finishing.
• Measure, mix, apply, and control repair materials according to specified ratios, working times, layer schedules, cure conditions, and shelf-life limits.
• Recognize surface, laminate, structural, dimensional, and cure defects; distinguish authorized repairs from work requiring escalation.
• Demonstrate visual attention, manual dexterity, hand-eye coordination, contour awareness, and patience for detailed repair and finish work.
• Document repairs and clearly communicate status, risks, delays, recurring damage, and release needs.
• Work safely with chemicals, fiberglass, dust, noise, powered tools, moving equipment, and changing production priorities.
• Maintain dependable attendance and work the assigned schedule and required overtime. Perform essential physical and sensory functions with or without reasonable accommodation.

Preferred Experience

• Fiberglass, composite, tooling, mold repair, gel-coat repair, surface restoration, laminating, body repair, marine repair, recreational-vehicle repair, or similar finish-sensitive work.
• Diagnosing cracks, chips, voids, delamination, porosity, worn surfaces, damaged edges, and contour defects and selecting an approved repair method.
• Resin systems, fiberglass reinforcement, fillers, tooling surfaces, catalysts or hardeners, controlled cure, sanding, polishing, and release preparation.
• Drawings, templates, gauges, inspection lighting, material-lot records, repair travelers, work orders, and maintenance systems.
• Work under a defined repair-authorization matrix with Quality, Engineering, tooling, or supervisory release requirements.
• Applicable training in hazard communication, respiratory protection, powered tools, lockout/tagout, lifting devices, fall protection, or hazardous-waste control.

Working Relationships and Training

Work with the Mold Maintenance Supervisor or Lead for priorities, repair class, authorization, progress, and escalation; Mold Maintenance Operators for mold transfers, history, cleaning, and waxing; Production supervisors, line leads, and operators for mold need dates, removal reasons, handling observations, and production impact; Quality for defect criteria, inspection, holds, acceptance, and release evidence; Engineering or Tooling for structural, dimensional, recurrent, design-sensitive, or major repairs; EHS for exposure and safety controls; Materials or Purchasing for material availability, shelf life, storage, lot traceability, and replenishment; and HR and Training for required qualifications and training records.

• Complete site and repair-area orientation, emergency-response, traffic, housekeeping, hazard-communication, chemical-compatibility, spill-response, waste-control, PPE, and respiratory-protection training applicable to the assignment.
• Qualify on assigned tools, guards, abrasives, ventilation, dust collection, stands, carts, lifting aids, mold positioning, machine safety, and energy-control boundaries.
• Demonstrate damage assessment, repair classification, escalation, surface preparation, reinforcement, material control, layer schedules, contour restoration, cure, sanding, polishing, finishing, inspection, and release documentation.
• Complete supervised repairs by class, knowledge checks, practice and trainer observation, documented signoff, required retraining, and periodic requalification. Follow shelf-life, lot-tracking, mixing, storage, contaminated-material, cure-before-disposal, and approved waste-container requirements.

Performance Indicators

• Repair turnaround time by defect or repair class and first-pass acceptance after return-to-service review.
• Reduction of repeat damage, repeat repairs, mold-related downtime, product defects, rework, and scrap after repair.
• Repair backlog and aging, schedule adherence, and on-time mold availability.
• Accurate repair records, material traceability, cure status, holds, approvals, and completion information.
• Effective material use, timely communication of delays, safe work, housekeeping, and contamination control.

Pay: $17.10 per hour

Expected hours: 40.0 per week

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Employee assistance program
• Health insurance
• Life insurance
• Paid jury duty
• Paid time off
• Parental leave
• Referral program
• Vision insurance

Experience:

• Fiberglass: 1 year (Preferred)

Shift availability:

• Day Shift (Required)

Ability to Commute:

• Martinsburg, WV 25404 (Required)

Work Location: In person