Flexo Folder Gluer Operator Assistant

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, Gopfert, 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 (up to 12-hour shifts).
• 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.

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Benefits

We offer a comprehensive benefits package to our employees, which includes:

• Medical Insurance
• Vision & Dental Insurance
• Life Insurance
• Matching 401(k)
• Commuter Benefits
• Employee Discounts & Rewards
• Payroll Payment Options

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