Flexo Technical Training & Process Specialist

The Flexo Technical Training & Process Specialist is responsible for developing the technical capabilities, consistency, and overall performance of Flexographic Operators, with primary emphasis on Book Presses, Finishing Equipment (Delta & ABG), and Specialty products and processes. This position serves as a hands-on technical resource and coach responsible for onboarding and training operators, evaluating operator capabilities, identifying skill gaps, and recommending development plans necessary to achieve operational, quality, and productivity expectations. The position also supports New Product Launch activities and the introduction of new or technically challenging work into production. When production issues arise, this individual is expected to determine whether the issue is related to equipment, process, materials, job setup, or operator behavior and take a lead role in coordinating the appropriate corrective action. While the primary focus of the position is training, technical development, and process support, the employee must be capable and willing to operate flexographic presses, Book Presses, Finishing Equipment, or other assigned production equipment when necessary to support operational needs.

This position does not have direct supervisory responsibility; however, it provides technical leadership, coaching, operator assessment, and recommendations to Operations Leadership regarding operator qualification, development needs, equipment assignments, and production readiness. Formal disciplinary action remains the responsibility of Operations Management.

• →Performs other related duties as assigned.
• →Demonstrates the behaviors of punctuality, regular attendance, professionalism towards supervisors and co-workers, and self-directed task completion.
• →Maintains clean work area.

• →Must comply with all departmental SOP's (Standard Operating Procedures), company GMP's (Good Manufacturing Practices), Employee Handbook Policies, including attendance, and all safety rules and standards.

Works normal shift hours and overtime as required, including schedule adjustments necessary to support training and technical needs across shifts.

Coordinates efforts as part of the team to provide assistance to all co-workers in all departments to maximize production efficiencies as needed.

• →Leads the technical onboarding and training of new Flexo Operators and employees assigned to Book Presses, Finishing Equipment (Delta & ABG), and Specialty operations.
• →Develops and executes structured training plans that progress employees from basic equipment operation through independent operation and technical proficiency.
• →Provides hands-on instruction covering machine setup, operation, changeovers, troubleshooting, quality requirements, productivity expectations, and proper operating practices.
• →Operates flexographic presses, Book Presses, Finishing Equipment, or other assigned production equipment as necessary to support production requirements, operator training, troubleshooting, new-product launches, or short-term coverage needs.
• →Evaluates operator technical capabilities through direct observation and practical demonstration and maintains objective assessments of operator competency and readiness.
• →Identifies individual skill gaps and establishes appropriate retraining, coaching, or development plans.
• →Makes recommendations to Operations Leadership regarding operator qualification, additional training needs, equipment assignments, and overall technical readiness.
• →Provides refresher and corrective training when recurring quality, productivity, setup, equipment, or operator-related issues are identified.
• →Reinforces standardized work practices and ensures operators understand both how processes are to be performed and why established procedures are required.
• →Assists in developing and maintaining training documentation, qualification criteria, standard work, troubleshooting guides, and other technical training materials.
• →Serves as a primary technical resource for Book Presses, Finishing Equipment, and Specialty production processes.
• →Provides hands-on production support for technically difficult jobs, new products, and recurring operational issues.
• →Troubleshoots equipment, setup, process, material, and operator-related issues and works with the appropriate departments to identify root cause and implement corrective actions.
• →Differentiates between machine-related problems, material issues, process deficiencies, and operator behaviors to ensure the appropriate corrective action is taken.
• →Works directly with operators when behaviors or operating practices contribute to quality defects, waste, downtime, or productivity issues.
• →Partners with Maintenance and Technical Services when equipment issues require mechanical or technical intervention and assists Operations Leadership in identifying recurring issues requiring longer-term corrective action.
• →Promotes consistent operating practices across shifts and equipment.
• →Participates as the Operations technical representative in New Product Launch meetings as assigned.
• →Reviews new products and specialty applications from a manufacturing and operator-readiness perspective, identifying risks involving equipment capability, tooling, materials, operator skill requirements, finishing requirements, and special processing needs before production.
• →Ensures appropriate operators are prepared and trained prior to production of new or technically challenging products and provides hands-on support during initial production runs and critical launches.

Monitors new products as they move through production to ensure established manufacturing requirements are followed and coordinates with Scheduling and Operations Leadership when additional technical support or specific operator capabilities are required.

Takes a lead role in troubleshooting production issues during new-product launches to minimize downtime, correct operator behaviors or machine issues, and prevent unnecessary delays.

• →Captures lessons learned from new-product launches and incorporates those learnings into future training and standardized processes.
• →Reviews recurring downtime, waste, quality defects, setup issues, and production challenges to identify opportunities for operator development or process improvement.
• →Works with Operations and Quality to identify trends where additional operator training could reduce repeat quality complaints or internal defects.
• →Recommends improvements to operating procedures, training methods, machine setup practices, and workflow and supports root-cause investigations involving operator technique, equipment setup, or production processes.
• →Assists leadership in establishing measurable technical competency expectations for Flexo Operators and supports cross-training initiatives to increase departmental flexibility and technical depth.
• →Promotes accountability, ownership, continuous improvement, and adherence to established manufacturing standards.

• → 

• Strong technical knowledge of flexographic printing, converting, finishing, and related manufacturing processes.
• Advanced knowledge of Book Presses, Finishing Equipment, Specialty converting processes, or similar equipment.
• Strong mechanical aptitude and demonstrated troubleshooting ability.
• Ability to evaluate machine performance and distinguish equipment problems from process, material, setup, or operator-related issues.

Ability to objectively assess operator technical competency and provide clear recommendations to management.

Strong coaching, training, and technical leadership skills with the ability to work effectively with employees at varying levels of experience.

Ability to correct ineffective operator behaviors in a professional, constructive, and consistent manner.

Strong understanding of manufacturing quality standards and the relationship between machine setup, operator practices, materials, and finished-product quality.

Ability to read and understand work instructions, job specifications, proofs, quality requirements, and manufacturing documentation.

Strong analytical, problem-solving, and root-cause-analysis skills.

Excellent verbal, written, interpersonal, and organizational skills.

Ability to work collaboratively across Operations, Quality, Maintenance, Scheduling, Customer Service, Graphics, and Technical Services.

Ability to prioritize multiple responsibilities and function effectively in a high-paced and at times stressful manufacturing environment.

Ability to exercise sound independent judgment and escalate issues appropriately.

Minimum of five years of progressive experience in flexographic printing, converting, finishing, or a closely related manufacturing environment preferred. Demonstrated experience troubleshooting production equipment and manufacturing processes required. Previous experience training, mentoring, or developing operators strongly preferred. Experience with book manufacturing, feeding systems, Delta and ABG finishing/converting equipment, and specialty label products is highly desirable. Previous experience supporting new-product introductions or technically complex manufacturing projects preferred. Supervisory experience is beneficial but not required. Equivalent combinations of education, technical training, and relevant manufacturing experience may be considered.

Frequently required to stand and walk for extended periods while working in a manufacturing environment.

Regularly required to reach with hands and arms and to use hands to handle, operate, or inspect equipment and materials.

Regularly required to talk or hear.

Must be able to bend, stoop, kneel, and move around production equipment as required for training and troubleshooting activities.

Must be able to lift and/or carry up to 25 pounds and occasionally lift and/or carry up to 50 pounds with appropriate assistance as required.

Specific vision abilities required by this job include close vision, color vision, depth perception, and ability to adjust focus.

While performing the duties of this job, the employee regularly works in a manufacturing environment and may be exposed to moving mechanical parts, printing inks and chemicals, dust, vibration, and other conditions typical of a printing and converting operation. The noise level in the production environment can be moderate to loud, and required personal protective equipment must be worn in designated areas.