Position Summary: We are seeking an experienced and motivated Flexo Folder Gluer Operator Assistant to join our high-performance production team within the corrugated packaging industry. This position plays a vital role in assisting in the operation of multi-color flexographic printing presses integrated with rotary die cutting, folding, and gluing systems. The ideal candidate will have a background in flexo press setup and converting operations and knowledge of box manufacturing processes. This is a hands-on role focused on safety, product quality, and maximizing up time in a fast-paced, high-volume environment. Major Responsibilities:
Member of a a press crew of 3 or more team members with a strong emphasis on safety, quality assurance, housekeeping, and machine performance.
Assist in collaborating cross-functionally with Design, Client Services, Scheduling, Sales, and Maintenance teams to ensure efficient job setups and on-time order fulfillment aligned with customer specifications.
Assist in the operation and set up a variety of Flexo Folder Gluer equipment (e.g., Ward, Bobst, Martin, Göpfert, or equivalent) per production specifications and work orders.
Assist in the configuration and fine-tune machine components including:
Print decks (anilox rolls, doctor blades, ink pans)
Registration systems, die cut sections, and slotting knives
Feeder, folding arms, vacuum transfer, and delivery sections
Glue systems (cold or hot melt, extrusion nozzles, pattern controllers)
Compression and bundling systems
Assisting in performing detailed inspections of incoming board stock and in-process production to meet internal quality standards and customer expectations (ISO/GFSI compliance where applicable).
Assist in monitoring and optimizing press run speeds, ink and glue application, registration accuracy, and folding alignment to minimize waste and maximize output.
Escalate complex mechanical or electrical issues to the Maintenance Team and provide accurate feedback for root cause analysis.
Accurately record production output, waste, downtime codes, and other job metrics into ERP systems (e.g., Amtech, ScoreKeeper, or similar).
Daily Responsibilities:
Assist in conducting complete machine setups including print plate mounting, anilox selection, viscosity checks, and folder/gluer calibration.
Assist in performing startup checks for print quality, board integrity, glue application, and die cut accuracy.
Input real-time data into production systems, including shift performance, downtime reasons, and quality rejects.
Perform housekeeping tasks in compliance with 5S standards and lean practices.
Maintain ink and glue systems by checking viscosity, cleanliness, and proper flow.
Weekly Responsibilities:
Help in coordinating with Maintenance and Supervision to perform and schedule preventative maintenance tasks such as:
Help with lubrication, belt tensioning, anilox roll cleaning, and inspection of folding elements.
Provide feedback on setup times, job changeovers, and identify opportunities for standard work improvements.
Support onboarding and training of new Flexo crew members and cross-train on auxiliary equipment (e.g., rotary die cutters, stackers).
Actively participate in toolbox talks and safety meetings.
As-Needed Responsibilities:
Participate in Kaizen events, SOP updates, and operator-led quality audits.
Assist with customer trial runs, prototyping, or first-article inspections for new product launches.
Ensure proper handling, labeling, and disposal of inks, adhesives, and corrugated scrap per company and environmental guidelines.
Other duties as assigned
Skills & Qualifications:
Strong mechanical aptitude with experience troubleshooting and fine-tuning high-speed flexographic printing and folding/gluing lines.
Solid understanding of corrugated board grades, flute profiles, and how substrate characteristics impact print, fold, and glue performance.
Experience with multi-color flexo systems (2-4+ color decks), inline rotary die cutting, and folder-gluer operation.
Proficient in reading job tickets, CAD drawings, die lines, and customer print specs.
Competence in Microsoft Office, ERP systems, and manufacturing reporting tools.
Familiarity with LEAN manufacturing, 5S, and continuous improvement practices.
Physical Requirements:
Ability to stand, bend, and lift for extended periods.
Must be able to lift up to 50 lbs and operate equipment in a manufacturing environment.
Tolerance to noise, dust, and adhesives commonly found in corrugated facilities.