The Plant Machinery Operator is responsible for safe, efficient setup, operation, and minor maintenance of assigned production equipment within the corrugated box plant. The role ensures consistent output quality, optimal machine utilization, adherence to safety standards, and timely completion of production orders.
Key Responsibilities
Production & Operation
Set up and operate assigned machinery as per SOP and job card (order specs: flute type, board grade, dimensions, print details).
Monitor machine parameters (speed, temperature, pressure, ink viscosity, adhesive solids/gel temp, moisture/warp) and adjust to maintain quality and throughput.
Ensure correct materials are loaded (reels, liners, mediums, inks, plates/dies, adhesives, stitching wire) and aligned for minimal waste.
Conduct start-up, in-process, and end-of-line checks; record results in production logs or MES.
Minimize downtime through proactive changeover planning and quick troubleshooting.
Quality Assurance
Inspect board and boxes against specifications (ECT/BCT, caliper, edge alignment, print registration, slot/die accuracy, glue/stitch strength).
Segregate and report nonconforming product; support root cause analysis (RCA).
Maintain traceability for reels/inks/glues and job components.
Safety & Compliance
Strictly follow LOTO, PPE, and machine guarding protocols.
Maintain housekeeping (5S), ensure clean work area, and safe material handling.
Report hazards, near-misses, and incidents immediately.
Maintenance & Documentation
Perform routine checks: lubrication, belt/tension inspection, blade/knife wear, sensor alignment, ink circulation.
Assist maintenance teams during breakdowns and scheduled PM.
Complete daily shift reports, production data, and downtime logs accurately.
Teamwork & Continuous Improvement
Coordinate with preheater/adhesive kitchen, QA, logistics, and maintenance.
Participate in kaizen/lean initiatives (waste reduction, setup time, changeover optimization).
Train and guide helper/operators during shifts and cross-train across machines.
Qualifications
Experience:
1-5 years operating production machinery; corrugation industry experience preferred.
Technical Skills:
Ability to read job cards, machine panels, gauges, calipers, micrometers.
Basic troubleshooting of mechanical/drive issues, sensor alignment, pneumatics.
Familiarity with adhesives (starch preparation), ink systems, and print/die registration.
Basic computer literacy (HMI/MES/ERP entries).
Physical & Work Environment Requirements
Ability to stand for extended periods and handle moderate-to-heavy materials (up to 25-30 kg with aids).
Exposure to heat/noise/steam/inks/adhesives; PPE usage mandatory.
Willingness to work rotating shifts, weekends, and overtime during peak demand.
KPIs & Performance Metrics
Output:
OEE %, machine uptime, boards/boxes per hour, changeover time.