Modular Converting Operator

Location: Dayville

Job Title:

Modular Converting Operator

Date Prepared: 1/13/2026

Department:
Operations

Reports To (Title):
Shift Supervisor

TO BE COMPLETED BY HUMAN RESOURCES:

FLSA Status:
Non-Exempt Exempt

Job Code:
Salary Grade:

POSITION SUMMARY

Please provide a brief, high-level description stating the essential responsibilities of the position. The summary should be no longer than 3 to 4 sentences and should provide a general synopsis of the job in as few words as possible.

The Modular Converting Operator is responsible for independently setting up, operating, optimizing, and troubleshooting a modular converting press to manufacture high-quality, multi-layer products involving die-cutting, lamination, and printing processes. This role requires advanced technical expertise to ensure product quality, throughput, yield optimization, and on-time delivery while maintaining compliance with ISO and regulatory standards. The Operator serves as a key technical resource, supporting Engineering, Quality, and Manufacturing through customer trials, new product introductions, and continuous process improvement initiatives.

PRINCIPAL DUTIES AND ESSENTIAL FUNCTIONS:

This section should list up to 10 principal tasks and functions that are considered to be fundamental to the position, establishing expectations for the job to which the individual will be held accountable and are critical to the successful performance of the job. Duties that the employee must be able to perform with or without reasonable accommodation must be included in this section.

Check if this is an essential function of the job

Advanced Machinery Operation & Process Control

• Independently set up, configure, and operate a modular converting line in accordance with standard work, engineering specifications, and customer requirements.
• Assemble, configure, and optimize nip stations, winders, spindles, web guides, slitter stations, die stations, and flexographic printing units.
• Load, verify, and adjust HMI recipes and controller parameters to ensure accurate machine configuration and repeatable performance.
• Web up materials following defined order-of-operations to minimize waste, maximize yield, and protect product integrity.
• Establish, maintain, and optimize web tensions, registration, and alignment throughout the production run.
• Perform real-time ("on-the-fly") adjustments to gear ratios, spindle tensions, nip pressures, die pressures, and registration to maintain process stability and product specifications.
• Utilize vision systems, test data, and process metrics to proactively identify trends and make data-driven adjustments.

Quality, Documentation and Compliance

• Execute standard quality control tests and inspections to verify finished product conformance to specifications.
• Ensure strict adherence to ISO requirements, standard work, and batch documentation practices during product and/or lot changes.
• Accurately complete and maintain all production, quality, and lot traceability documentation.
• Support root cause analysis and corrective actions related to quality, yield loss, or process deviations.

Production Performance and Systems Use

• Achieve or exceed defined production targets for throughput, yield, scrap reduction, and uptime.
• Accurately navigate and update ERP systems throughout the production run to ensure real-time production visibility.

Follow standardized setup, run, and teardown procedures across multiple product types with minimal supervision.

• Demonstrate a strong understanding of how tension zones, materials, and tooling interactions affect process capability and product quality.

Troubleshooting & Equipment Optimization

• Independently troubleshoot mechanical, process, and control-related issues on the modular converting line.
• Identify emerging issues before failures occur and take corrective action or escalate appropriately.
• Partner with Engineering and Maintenance to diagnose complex problems and implement sustainable solutions.

Safety & Environmental Compliance

• Consistently comply with all safety rules, policies, and safe work practices.
• Actively identify, report, and address unsafe conditions, near misses, and incidents.
• Demonstrate ownership of environmental compliance by promptly reporting potential environmental concerns.
• Serve as a role model for safe behavior and adherence to manufacturing and regulatory standards.

Process Improvement & Maintenance

• Maintain tooling, spare parts, and point-of-use equipment in a production-ready condition.
• Actively contributes to continuous improvement initiatives focused on reducing downtime, improving yields, and increasing throughput.
• Apply lean manufacturing principles to identify inefficiencies and recommend process improvements.
• Communicate maintenance needs clearly and accurately, support maintenance activities including PMs, module inspections, cleaning, and minor adjustments.
• Support structured problem-solving efforts (e.g., Kaizen, root cause analysis, SMED initiatives).

Training & Technical Leadership

• Maintain accurate and current training records and…