Lead Operator Flexo -Folder-Glue (2 or 3 Color)

Purpose of Role

As the Lead Flexo-Folder-Gluer Lead Operator, you will serve as the primary steward of one of our key converting machine centers. You are empowered to ensure that every job run on this machine delivers perfect boxes, minimal waste, rapid and accurate set-ups, and timely responsiveness to schedule changes. You will lead a crew of Operators and Production Associates, act as an expert on machine performance and maintenance, and drive continuous improvement in quality, safety, and productivity.

Key Responsibilities

(Ranked in priority: Safety → Quality → Production)

Safety & Compliance

• Ensure the work-area and machine center comply with all safety policies, lock-out/tag-out procedures, house-keeping standards (5S), and personal protective equipment rules.
• Lead by example: stop the line for unsafe conditions or quality risk, and coach your crew to do the same.
• Participate in safety audits, incident investigations, and training sessions; ensure corrective actions are implemented.

Machine & Process Ownership

• Set up, calibrate and operate the FFG machine: feeders, print stations, gluing system, folding/creasing section, scoring and slotting and stacker.
• Mount print plates, register ink units, set folding rails, adjust feeder/tray alignment and glue dosing.
• Conduct make-ready and test runs, ensure sample approval before full production begins.
• Monitor machine parameters during run-time: speed, waste levels, glue coverage, registration stability, box quality.
• Perform daily maintenance checks and change-parts: tooling, gluing systems, feeders, guides, delivery systems, belts, folding fingers, glue nozzles, sensors; escalate mechanical/electrical issues to maintenance.
• Lead change-overs: coordinate sheet substrate, tools, blanks, print plates and job data; minimize downtime and waste at each job transition.

Quality & Productivity

• Ensure every job meets customer print and structural specifications. Inspect incoming substrate, monitor throughout run and approve final output. Ensure a single folder carton is placed on every box.
• Continuously monitor scrap and waste levels; lead root-cause investigations for defects, machine inefficiencies or change-over delays.
• Track and report production metrics – set-up time, run time, waste %, uptime, throughput. Ensure accurate reporting to supervisor and shift team
• Drive the “three key production things” at Tavens: 1. Perfect Boxes, 2. Fast, Accurate Set-Ups, 3. Responsive Manufacturing — champion these in your team.

Crew Leadership & Development

• Lead, mentor and develop the Operators and Production Associates assigned to your machine center. Ensure they are competent on standard work, change-over procedures, quality checks and safety practices.
• Assign crew tasks, adjust staffing and roles in real time to best meet schedule, quality and machine performance requirements.
• Conduct or coordinate training/certifications (e.g., Basic Box-Maker → Advanced Box-Maker) for your team, particularly focused on this machine center.
• Encourage and coach ownership mindset: team members understand how their work impacts box quality, setup speed and responsiveness to schedule changes.

Collaboration & Continuous Improvement

• Work closely with Material Handling and Tooling to ensure tooling availability, substrate readiness, job scheduling alignment, and machine availability.
• Identify opportunities to reduce set-up time, reduce waste, improve machine uptime, optimize glue usage, and improve operator skill. Lead or participate in kaizen or continuous improvement projects.
• Update standard-work and change-over checklists to reflect improvements or best-practice learnings.
• Communicate effectively to your supervisor and cross-functional leads: machine status, upcoming jobs, material/tooling status, deviation from schedule, and improvement ideas.

Qualifications & Experience

• High school diploma or equivalent required.
• Minimum 3-5 years of experience operating a Flexo Folder-Gluer machine in a corrugated converting environment.
• Proven mechanical aptitude: ability to set up feeders, adjust folding/folder rails, glue systems, ink registration, and troubleshoot machinery.
• Experience leading or mentoring a small crew of production staff or operators.
• Demonstrated ability to read job tickets/specifications, understand print/structural requirements, and enter/interpret production data.
• Strong communication skills, teamwork and leadership mindset.
• Reliable attendance, ability to work shift schedule (including early starts, overtime, weekends as plant needs).
• Physical requirements: ability to stand for long periods, bend, lift up to ~50 lbs, work around noise, dust and industrial manufacturing environment.

Pay: $18.00 - $26.00 per hour

Benefits:

• 401(k)
• Dental insurance
• Health insurance
• Health savings account
• Life insurance
• On-the-job training
• Paid time off
• Vision insurance

Work Location: In person

Salary : $18 - $26