Key Responsibilities and Required Skills for Flexpack Operator

🎯 Role Definition

As a Flexpack Operator, you will be at the heart of our production process, responsible for the complete lifecycle of our flexible packaging products. From initial machine setup and material handling to final quality inspection and documentation, you will ensure our operations run smoothly, safely, and efficiently. This position requires a hands-on individual who thrives in a fast-paced manufacturing environment and is committed to upholding the highest standards of quality, safety, and productivity. You will be a key player in our success, directly impacting the quality of the products that reach consumers every day.

📈 Career Progression

Typical Career Path

Entry Point From:

Production Assistant
Machine Operator Helper
General Laborer (Manufacturing)

Advancement To:

Lead Flexpack Operator
Production Supervisor
Quality Control Technician

Lateral Moves:

Maintenance Technician
Slitter or Lamination Specialist

Core Responsibilities

Primary Functions

Execute the complete setup, calibration, and changeover of complex flexible packaging machinery (e.g., pouch makers, bag machines, laminators) according to detailed job specifications.
Operate and diligently monitor high-speed equipment during production runs to ensure continuous operation, consistent quality, and optimal output.
Read, interpret, and strictly follow production schedules, work orders, and technical specifications to ensure accurate output that meets customer deadlines.
Conduct rigorous and frequent in-process quality control checks, visually inspecting for defects such as poor seals, incorrect dimensions, printing errors, and material flaws.
Utilize precision measurement tools, including calipers, micrometers, and rulers, to verify that finished products meet strict dimensional and quality assurance standards.
Safely handle and load large, heavy rolls of raw materials like films, foils, and papers onto machine unwind stands and perform splices for continuous, uninterrupted runs.
Proactively troubleshoot machine malfunctions and process variations, making necessary mechanical and system adjustments to correct issues, minimize downtime, and reduce material waste.
Perform routine and preventative maintenance on equipment, including cleaning, lubricating, and replacing minor parts, to maintain peak performance and extend machinery lifespan.
Accurately complete all required production and quality documentation, meticulously recording output quantities, scrap rates, downtime, and quality check results in logbooks or computer-based systems (MES/ERP).
Adhere strictly to all plant safety protocols, including Lock-Out/Tag-Out (LOTO) procedures, proper use of Personal Protective Equipment (PPE), and adherence to machine guarding standards.
Maintain a clean, organized, and safe work area in accordance with 5S principles and Good Manufacturing Practices (GMP) to ensure a world-class production environment.
Collaborate effectively with team members, supervisors, maintenance, and the quality assurance department to resolve production challenges and drive continuous improvement initiatives.
Set up and monitor slitting and rewinding equipment to precisely cut master rolls of material into finished rolls of specific widths and lengths as per customer orders.
Manage the staging of raw materials and the efficient removal of finished goods and scrap from the production floor to maintain an optimal workflow.
Assist in the training, coaching, and mentoring of new or less experienced operators on machine functions, safety procedures, and quality standards.
Mount and register printing plates or cylinders for jobs requiring in-line printing, ensuring correct color saturation, registration, and overall print quality.
Monitor and adjust ancillary equipment such as web guides, corona treaters, and tension control systems to ensure consistent material flow and superior product quality.
Take full responsibility for packaging finished products, creating accurate labels, and palletizing goods for safe and efficient transfer to the warehouse or shipping department.
Proactively identify and report opportunities for process improvements related to safety, quality, waste reduction, and operational efficiency.
Utilize HMI (Human Machine Interface) control panels to operate machine functions, diagnose faults, adjust settings, and access production recipes.

Secondary Functions

Support ad-hoc projects related to new material trials, equipment testing, or machine capability studies.
Contribute actively to daily team meetings by providing clear updates on production status, challenges, and potential solutions.
Collaborate with the maintenance department to schedule major repairs and provide detailed information on machine performance issues to facilitate quick resolution.
Participate in periodic inventory counts of raw materials, work-in-progress, and production supplies.

Required Skills & Competencies

Hard Skills (Technical)

3+ years of hands-on experience operating flexible packaging equipment (e.g., Totani, Mamata, CMD, Bobst, Nordmeccanica).
Strong mechanical aptitude for machine setup, troubleshooting, fine-tuning, and performing minor repairs.
Ability to read and interpret technical documents, engineering drawings, and complex work orders.
Proficiency in using precision measurement tools like tape measures, digital calipers, and micrometers.
Solid understanding of various packaging films, laminates, adhesives, and their unique properties.
Basic computer proficiency for data entry into Manufacturing Execution Systems (MES) or Enterprise Resource Planning (ERP) software.
In-depth knowledge of Good Manufacturing Practices (GMP), food safety standards, and SQF/BRC requirements.
Certified or demonstrably proficient in performing Lock-Out/Tag-Out (LOTO) safety procedures.

Soft Skills

Exceptional attention to detail with a relentless commitment to producing high-quality work.
Strong analytical and problem-solving skills to diagnose and resolve issues efficiently.
Excellent verbal and written communication skills for effective collaboration with the team.
Ability to work independently with minimal supervision and manage time effectively in a dynamic, fast-paced environment.
A high degree of safety consciousness and situational awareness at all times.
Physical stamina and strength to stand for extended periods and comfortably lift up to 50 lbs.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED.

Preferred Education:

Technical or Vocational school certificate in a mechanical or manufacturing-related field.

Relevant Fields of Study:

Industrial Maintenance
Manufacturing Technology
Machine Tool Technology

Experience Requirements

Typical Experience Range: 2-5 years of experience as a machine operator in a high-speed manufacturing environment.

Preferred: 3+ years of direct, hands-on experience specifically operating flexible packaging machinery, such as pouching, form-fill-seal, lamination, or slitting equipment.