Utility Operator- ConvertingThe Utility Operator – Converting is a cross-trained, multi-machine operator who provides flexible, skilled coverage across the converting department. Unlike an operator assigned to a single machine, the Utility Operator is expected to run effectively on multiple pieces of equipment — flexo folder gluers, die cutters, the bundler, and the stitcher — and to move between assignments as production demand, staffing, and scheduling require.This role is the converting department's operational flexibility. A strong Utility Operator reduces the impact of absenteeism, fills machine gaps during peak periods, and accelerates throughput when specific lines need surge coverage.
The ideal candidate is technically proficient, adaptable, and self-directed — someone who can take an assignment, confirm their setup, and run to standard without close supervision.Key Responsibilities & Expected Results:Operate assigned converting equipment safely and to production standard — including flexo folder gluers, die cutters, bundler, and stitcherSet up assigned equipment at shift start: confirm dies, plates, scores, glue settings, and any job-specific parameters before running first pieceComplete first-piece verification on every order before full production begins; do not advance to full run without confirming specAdjust machine settings as needed during the run to maintain output quality and speedTransition between equipment assignments within or across shifts as directed by the Lead or SupervisorInspect in-process product throughout the run — check dimensions, print registration, score/slot positions, glue integrity, and bundle/stitch qualityStop the run immediately if product is out of spec; notify the Lead and initiate a quality hold per SOPVerify order count accuracy; do not release an order to staging with an unresolved count discrepancyComplete all required quality check forms and attach job ticket documentation before releasing finished goodsLog all downtime events with the correct reason code, machine, and elapsed time — no blank reason codesAttempt operator-level troubleshooting (feed adjustments, minor jams, glue system resets) before calling for helpEscalate mechanical, electrical, or recurring issues to the Lead immediately — do not continue running on a known problemReport setup delays, material issues, or ticket discrepancies to the Lead at the time they occur, not at end of shiftFollow all LOTO (lockout/tagout) procedures before performing any cleaning, adjustment, or clearing of jams on equipmentWear all required PPE for each machine and task — compliance is non-negotiableMaintain a clean, organized work area throughout the shift; complete 5S housekeeping duties before leaving the machineReport any unsafe condition, near-miss, or injury to the Lead immediatelyCommunicate run status, open issues, and pending setups to the incoming operator or Lead at shift changeLeave equipment in a clean, safe state at end of shift — no mid-job jams, no materials left in feeders without documentationParticipate in pre-shift huddles and follow any task assignments or priority changes from the LeadEquipment coverage & Skill ProgressionThe Utility Operator role is defined by multi-machine competency. The following matrix is used to track each operator's current clearance level. Operators are expected to expand their clearance profile over time through structured cross-training.Equipment / Task - Competency Level - Cleared to Run SoloFlexo Folder Gluer - ___________________ - YesIn TrainingDie Cutter - ___________________ - YesIn TrainingBundler - ___________________ - YesIn TrainingStitcher - ___________________ - YesIn TrainingInk / Color Kitchen Support - ___________________ - YesIn TrainingQualifications and Skills / Education and ExperienceAbility to learn and operate multiple types of converting equipment through structured on-the-job trainingAbility to read and interpret job tickets, print layouts, and material/order specificationsReliable attendance and punctuality — this role is a coverage position; unplanned absences directly impact productionDemonstrated attention to detail in a production or manufacturing environmentAbility to follow written and verbal instructions and complete required documentation accuratelyHigh School/ GED diplomaPrior experience operating converting equipment — flexo folder gluers, die cutters, bundler, or stitcher — in a corrugated or packaging environmentBilingual English/Spanish — strong preference given the composition of the production workforceFamiliarity with quality inspection, LOTO procedures, and 5S housekeeping standardsPrior experience in a utility, cross-trained, or float operator roleBilingual in Mandarin a plusPhysical RequirementsFrequent handling and positioning of rotary dies — team lift required above 50 lbs.; large-format dies may require mechanical assist.Standing and working at machine height for full shift duration (8–12 hours).Required PPE: steel-toed boots, safety glasses, cut-resistant gloves during all die handling, hearing protection in designated areas.What Success Looks Like-First 90 daysIn 30 days: The operator can run at least one machine type to standard with minimal supervision, completes first-piece verification on every order, and logs downtime with reason codes consistently.In 60 days: The operator is cleared on a second machine type and transitions between assignments without disruption to shift flow.
Quality check completion rate is consistent and accurate.In 90 days: The operator is cleared on three or more machine types, can be assigned to any available line without significant ramp time, and is identifying and escalating issues proactively rather than reactively.At 6 months: The operator is a dependable, flexible resource across the full converting floor — someone the Lead can assign to the highest-priority gap without concern about quality or output.Authority & Escalation GuidelinesThe Utility Operator – Converting has authority to:Stop a run that is producing out-of-spec product or creating a safety riskInitiate a quality hold per SOP and immediately notify the LeadPerform operator-level troubleshooting on assigned equipmentThe Utility Operator must escalate to the Converting Shift Production Lead or Supervisor when:A machine requires maintenance beyond operator-level interventionA quality issue requires a disposition decision or customer communicationAn order cannot be completed due to material, tooling, or specification problemsAny safety hazard, injury, or near-miss occursKey Performance Indicators (KPIs)Note: All metrics are in a 60–90 day baseline period. Targets will be set collaboratively after baseline data is established.Metric - Baseline Period - Target (Post-Baseline) - FrequencyMachine Output vs. Standard Run Speed - 60–90 days - TBD after baseline - Per shiftFirst-Piece Verification Completion Rate - 60–90 days - 100% documented - Per orderOrder Count Accuracy - 60–90 days - TBD after baseline - Per orderDowntime Reason Code Completion Rate - 60–90 days - TBD after baseline - Per shiftQuality Hold Compliance (SOP-QA-001) - 60–90 days - 100% - Per eventCross-Training Clearances Earned - 60–90 days - ?2 by 90 days - QuarterlySafety Incidents (recordable/near-miss) - 60–90 days - 0 recordable - Monthly5S Compliance Score - 60–90 days - TBD after baseline - WeeklyOnboarding MilestonesMilestone - Expected Outcome30 Days - Cleared on at