Modular Converting Operator

Web Industries Inc•Killingly, CT

1d•$27 - $36•Onsite

About The Position

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.

Requirements

High School diploma or GED
Minimum 1-3 years’ hands-on experience operating complex equipment in a manufacturing environment
Demonstrated understanding of standard measurements, tolerances, and ISO-controlled processes
Proficient in the use of measuring devices including rulers, calipers, and inspection tools.
Ability to read, interpret, and execute complex work instructions, process documentation, and technical drawings.
Basic computer proficiency including ERP systems and Microsoft Office applications.
Strong mechanical aptitude and troubleshooting skills.
Self-motivated, detail-oriented, and capable of maintaining focus in a fast-paced production environment.
Ability to lift up to 50 lbs and safely handle materials in a manufacturing setting.
U.S. Citizen or Permanent Resident.

Nice To Haves

Delta ModTech Advanced Training or equivalent modular converting system experience.
Lean Six Sigma Green Belt or formal Lean Manufacturing training.
Hands-on experience applying Lean tools such as SMED, Kanban, Poka-Yoke, and value stream mapping.
Experience manufacturing within regulated environments (e.g., ISO 13485, AS9100).
Associate degree in Engineering, Manufacturing Technology, or related field.
Demonstrated track record of strong performance, technical leadership, and effective communication.
Experience with vision systems, automation controls, and data-driven process optimization.
Background in industrial and/or consumer product manufacturing.

Responsibilities

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.
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.
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.
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.
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.
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).
Maintain accurate and current training records and obtain required competency signoffs.
Provide high-quality, hands-on training and mentoring for other operators.
Serve as a technical resource and subject matter expert on the modular converting line.
Support the continuous improvement of training materials, standard work, and onboarding processes.
Maintain a “customer-ready” production environment at all times.
Ensure point-of-use storage systems and Kanban inventories are accurately stocked and organized.
Actively support and sustain 5S and visual management standards.
Dependability: Demonstrates accountability, reliability, and consistency in performance and decision-making.
Judgment: Applies sound technical and safety judgment using structured problem-solving tools and data-driven analysis.
Can-Do Mentality: Proactively mentors others, embraces challenges, and applies Lean tools to drive results.
Communicates clearly and professionally across verbal, written, and electronic formats.
Works effectively with cross-functional teams including Quality, Engineering, Maintenance, and Production.
Demonstrates the ability to work independently with minimal direction while knowing when to escalate issues.
Acts as a team-oriented leader who supports production goals and company culture.
Performs any other function or responsibility as assigned.