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Position Summary

The Flexo Press Machine Operator Lead is a hands-on working lead responsible for the setup, operation, and quality output of flexographic printing presses (including the Mark Andy 8-color and Retroflex 4-color presses), while directing and developing a crew of press operators and helpers. This position serves as the first point of escalation on the press floor for quality, mechanical, scheduling, and personnel issues during the shift. The Lead ensures all jobs are run safely, to specification, on schedule, and in full compliance with company quality standards, customer specifications, and OSHA safety requirements.

Essential Duties & Responsibilities

Press Operation & Setup

• Perform complete press setups and changeovers: plate mounting, anilox roll selection, doctor blade setup, impression settings, registration, die-cutting setup, and web tension control.

• Operate the press to produce printed product meeting customer specifications for color, registration, print quality, and dimensional accuracy.

• Mix, monitor, and adjust inks (UV, water-based, solvent) including viscosity and pH control; verify ink and substrate match job specifications.

• Perform first-article inspections and obtain required approvals before running production; complete in-process quality checks at defined intervals per QA procedures.

• Troubleshoot print defects (misregistration, dot gain, streaking, pinholing, die-cut issues) and mechanical problems; escalate to maintenance when beyond operator-level repair.

• Accurately complete job tickets, production counts, waste tracking, end-of-shift reports, and quality documentation.

Lead Responsibilities

• Direct, train, and coach press operators, assistant operators, and material handlers assigned to the shift; model correct setup and operating technique.

• Assign work and coordinate press schedules with the Production Planner to meet delivery commitments; communicate schedule risks early.

• Serve as first responder for quality holds; stop production when product is out of specification and initiate containment per RCCA procedures.

• Support onboarding and cross-training of new operators; verify training completion and sign off on demonstrated competencies.

• Communicate shift-to-shift handoffs including press status, open issues, material shortages, and maintenance needs.

• Provide input to the Production Supervisor on crew performance, attendance issues, and disciplinary documentation; enforce plant policies on the floor (including the no-cell-phone policy in production areas).

Maintenance, Safety & Housekeeping

• Perform and verify daily/weekly operator preventive maintenance per press PM checklists; log maintenance requests for issues requiring the maintenance team.

• Enforce lockout/tagout, machine guarding, PPE, and all OSHA safety requirements; participate in safety meetings, audits, and incident investigations.

• Maintain 5S standards in the press area: organized tooling, labeled inks and plates, clean work surfaces, and clear aisles.

• Ensure proper handling, labeling, and storage of plates, dies, anilox rolls, and hazardous materials (inks, solvents, cleaning agents).

Inventory Management — Inks & Machine Parts

• Monitor on-hand levels of inks, solvents, additives, plates, doctor blades, and consumable press parts; notify the Purchasing Manager of reorder needs before stock-outs impact the schedule.

• Record ink usage, returns, and waste against jobs; ensure partial containers are properly labeled, dated, and stored for reuse (FIFO).

• Maintain an organized spare parts inventory for the presses (bearings, gears, seals, blades, tapes, sleeves); track critical spares and flag low quantities.

• Support accurate inventory transactions in NetSuite, including material issues to jobs and cycle counts of press-area supplies.

• Inspect incoming inks and parts against purchase orders; report shortages, damage, or discrepancies to Purchasing and the Warehouse Supervisor.

Qualifications

Required

• High school diploma or GED.

• Minimum 3–5 years of flexographic press operation experience, including full setups and changeovers on multi-color presses.

• Working knowledge of ink systems (UV, water-based, solvent), viscosity control, anilox selection, plate mounting, and rotary die-cutting.

• Demonstrated ability to read and interpret job tickets, customer spec sheets, and quality standards.

• Basic math skills (measurements, counts, percentages) and ability to use measurement tools (micrometers, densitometers, rulers/gauges).

• Strong troubleshooting skills and mechanical aptitude.

• Effective communication skills and the ability to lead and train others.

Preferred

• Prior lead, trainer, or supervisory experience in a printing or converting environment.

• Experience with Mark Andy and/or Retroflex press platforms.

• Experience printing security or regulated products (e.g., lottery playslips) with tight registration and inspection requirements.

• Familiarity with ERP/production systems (NetSuite) for job reporting and inventory transactions.

• Forklift certification (or ability to obtain per OSHA 29 CFR 1910.178).

Work Environment & Physical Requirements

• Manufacturing floor environment with exposure to noise, moving machinery, inks, and solvents; PPE required.

• Ability to stand and walk for the majority of an 8–12 hour shift.

• Ability to lift up to 50 lbs regularly and team-lift heavier rolls/tooling with equipment assistance.

• Frequent bending, reaching, pushing/pulling, and fine hand manipulation during setups.

• Visual acuity sufficient to detect print defects, verify color, and read gauges (with or without correction).

Performance Standards

• Product quality: first-pass yield, defect escapes, and adherence to QA-FLEX procedures.

• Productivity: setup/changeover times, run speeds, and waste percentage against targets.

• Safety: zero preventable incidents; completion of PM checklists and safety training.

• Leadership: crew training progress, shift handoff quality, and documentation accuracy.

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