Hey Ilja, how do you spend your free time?

I am a very sporty person. You can find me in the gym almost every day, doing weight training or calisthenics. This is a special form of weight training, but you only train with your own weight. I also like to meet my friends and play soccer as a hobby.

Can you tell me something in general about the apprenticeship as a process mechanic for plastics and rubber?

There are seven different specializations for the apprenticeship as a process mechanic for plastics and rubber technology:

• Molded parts
• Semi-finished products
• Multilayer rubber parts
• Compound and masterbatch production
• Components
• Fiber composite technology
• Plastic windows

I'm doing my apprenticeship in the field of semi-finished products and, as the name suggests, that's where you produce semi-finished plastic and rubber products. Semi-finished products are individual workpieces that are manufactured for further processing or assembly.

At RAUMEDIC, for example, this could be some individual tubes that are later assembled into a finished medical tube set. Only then does the hose set result in a finished product.

The semi-finished products are produced using various process technologies. Hoses are produced by extrusion and molded parts are produced by injection molding.

Could you please describe us your individual job in the production of these semi-finished products?

My main task as a process mechanic is to process production orders. Depending on which product is to be produced, I take care of the machines setup.

Setting up means converting the production lines for the desired production, i.e. equipping them with the appropriate tooling. After that, production can be started up: The machine is brought from the idle state into the functional continuous production - operated by us.

Through various measuring and testing activities, the resulting product is checked for defects or contamination.

When the desired quantity of semi-finished products has been produced, we then take care of retooling the machine again for new orders. Maintaining and cleaning the operating equipment is also part of the process mechanic's job.

I am accompanied every day by an experienced employee and also assisted if necessary.

Tell us about the training program of your apprenticeship as a process mechanic for plastics and rubber technology in the company.

The dual training program for process mechanics for plastics and rubber technology lasts 3 years. The minimum requirement for this apprenticeship is a secondary school leaving certificate.

My weekly working hours are exactly 40 hours and since I am already 18 years old, I work in a 3-shift system. That means I have a weekly change between early, late and night shift.

Sometimes I also work a weekend day once a month, but this is then paid out to me or credited to my working time account as a vacation day. I have 30 days of vacation per year.

During my apprenticeship, I alternate between the company, our training workshop in Rehau and the vocational school.

In the training workshop, I am trained in close connection with the work processes. Initially, so-called basic courses are taken there, such as the basic "metal" course. Later, more specific modules relating to the individual occupational field are added.

Before the apprenticeship begins, the department changes are scheduled. My main department is Thermoplast Extrusion, where we produce medical tubes. But during my apprenticeship I go through the entire production of RAUMEDIC, including the departments silicone extrusion, thermoplastic injection molding and silicone injection molding.

I will also be assigned to logistics, the workshop and quality management for a few weeks. My daily tasks vary depending on which products need to be produced.

How is your training at the vocational school organized?

I attend the vocational school in Rehau for a total of 12 weeks per year. Vocational school classes are always held for two weeks at a time in blocks.

Both theoretical and practical training content is covered in greater depth. During the school year, we write impromptu exams and school assignments in the various subjects.

My school subjects are for example:

• Construction elements
• Materials and processing
• Control engineering
• Product and process quality
• Extrusion and calendering
• Coating
• Foaming

There are also general education subjects such as German, religion and sports. The subject of construction elements deals with the manufacture of assemblies and components from job-related materials.

In the subject Materials and Processing, I learn how materials behave under the influence of heat or coldness and what properties I can recognize in materials. In control technology, we learn how to use and test control systems for processing plastics.

In product and process quality, I learn how to maintain the machines and tools and thus monitor and optimize quality. In the extrusion, calendering, coating and foaming area, we produce semi-finished products using the respective process.

At the end of the second year of the apprenticeship, we take the first part of the final examination. It counts 25% towards the overall result. This involves creating a test product and a written exam answering related questions.

The final examination part 2 again includes a theoretical and practical part. The practical part comprises a work task, which is then the subject of a situational discussion. The theoretical part covers the topics of process engineering systems, production planning and analysis, and economics and social studies.

In your opinion, what interests or talents should you have for the apprenticeship as a process mechanic for plastics and rubber?

In my view, you should definitely have manual dexterity and an interest in manufacturing a product from plastic. In addition, a certain understanding of numbers is important, since you have to calculate the wall thickness of a hose, for example.

Do you have any tips for those who are interested?

Do an internship! It gives you insights into the day-to-day work of a process mechanic and also into the team. I also did an internship before my apprenticeship.

Of course, I received a thorough briefing on my tasks. But I got involved right away. That was great! That's how I realized that I enjoy this job and it suits me.

Why did you choose RAUMEDIC for your apprenticeship?

RAUMEDIC is a very large and well-known employer in our region. Many of my friends are also currently apprentices at RAUMEDIC and have only told me positive things. After I really enjoyed my internship, it was clear to me that I wanted to work for RAUMEDIC.

What do you enjoy most about your work?

What I enjoy most is starting a completely new production job. First I change over the machine for the new production order. Then I clamp the tool onto the extruder and tell the material loader which material I need for the job.

I switch on the heaters and check all the necessary parameters. Then I center the hose so that it has a uniform wall thickness and becomes really round. I pull the extruded hose through the cooling basin until it arrives on the winder. This is how a new medical tube is created.

What do you think is special about the program at RAUMEDIC?

What I think is special at RAUMEDIC is the good way the company deals with the apprentices. As an apprentice, you are never left alone at a machine and are still allowed to work independently.

If I have any questions, I get help right away. At RAUMEDIC, a lot of emphasis is placed on proper training and we are seen as the future of the company.

That's just exactly what you are, the future of the company! Thank you Ilja – we wish you all the best with your training as a process mechanic for plastics and rubber specialized in semi-finished products!