Second pressman

Second Pressman – Komori GL540

Department: Sheetfed Press
Reports To: Lead Press Operator / Pressroom Supervisor
Classification: Full-Time, Hourly
Equipment: Komori Lithrone GL540 5-Color Sheetfed Offset Press

Position Summary

The Second Pressman supports the Lead Press Operator in the safe, efficient, and consistent operation of the Komori GL540 5-color sheetfed press. This position is responsible for assisting with press setup, plate and blanket changes, ink and coating preparation, paper handling, quality control, wash-ups, preventative maintenance, and troubleshooting.

The Second Pressman is expected to actively participate in running the press—not simply provide material support. The goal of the position is to maintain production efficiency, minimize waste and downtime, ensure consistent print quality, and develop the technical skills necessary to operate the press independently when required.

Essential Duties and Responsibilities

Press Setup & Makeready

• Assist the Lead Press Operator with daily press setup and makeready.

• Review job tickets, proofs, paper specifications, ink requirements, coatings, quantities, and finishing requirements before production.

• Load and remove printing plates accurately.

• Assist with blanket and packing changes.

• Prepare inks, coatings, wash solutions, and other pressroom materials.

• Stage paper and verify the correct stock, size, grain direction, quantity, and job identification.

• Set up and adjust feeder and delivery systems.

• Assist with registration, color, ink/water balance, and impression adjustments.

• Help achieve acceptable color and registration with minimum makeready sheets.

Press Operation

• Assist in operating the Komori GL540 throughout the production run.

• Monitor feeder operation and maintain consistent sheet feeding.

• Monitor delivery and properly handle completed loads.

• Maintain proper ink, fountain solution, coating, and consumable levels.

• Watch for marking, picking, scumming, doubling, slurring, registration movement, color variation, coating problems, and other print defects.

• Make routine press adjustments within the employee's level of training and responsibility.

• Communicate immediately with the Lead Press Operator when production or quality problems occur.

• Maintain an organized supply of paper, ink, plates, coatings, and other materials to minimize press downtime.

Quality Control

• Understand that both press operators are responsible for the quality of the finished product.

• Pull and inspect press sheets throughout the run.

• Compare production sheets against approved proofs, samples, and job specifications.

• Monitor registration, color consistency, density, dot reproduction, coating coverage, and overall appearance.

• Use densitometers, spectrophotometers, and other quality-control equipment as trained.

• Understand basic G7 principles, gray balance, density, TVI, and Delta E standards as applicable.

• Identify defects quickly and stop or slow production when necessary to prevent excessive waste.

• Ensure questionable product is identified and segregated rather than continuing through production.

Waste & Productivity

The Second Pressman shares responsibility with the Lead Press Operator for controlling pressroom waste and maintaining production efficiency.

• Minimize makeready sheets.

• Reduce unnecessary paper, ink, coating, and chemical waste.

• Help maintain established press speeds once acceptable quality is achieved.

• Keep feeder and delivery operations running efficiently.

• Anticipate upcoming press needs rather than waiting for the press to stop.

• Assist with rapid job changeovers.

• Accurately record waste, production counts, downtime, and other required job information.

• Immediately communicate mechanical or production issues that may create excessive downtime or waste.

Maintenance & Housekeeping

• Perform daily and scheduled operator-level preventative maintenance.

• Clean blankets, impression cylinders, rollers, pans, guards, and press components as required.

• Assist with roller and blanket inspection and replacement.

• Lubricate designated components according to the manufacturer's maintenance schedule.

• Monitor the press for abnormal sounds, vibration, leaks, wear, or other mechanical concerns.

• Report maintenance problems before they result in equipment failure whenever possible.

• Maintain a clean press, work area, and surrounding floor.

• Keep tools, chemicals, press supplies, and replacement parts properly stored.

• Participate in scheduled press cleaning and preventative maintenance.

Safety

• Follow all company safety policies and press-specific…