Modular Converting Operator

Job Title: Modular Converting Operator

Date Prepared: 1/13/2026

Department: Operations

Reports To (Title): Shift Supervisor

TO BE COMPLETED BY HUMAN RESOURCES:

FLSA Status: Non-Exempt Exempt

Job Code: Salary Grade:

POSITION SUMMARY

Please provide a brief, high-level description stating the essential responsibilities of the position. The summary should be no longer than 3 to 4 sentences and should provide a general synopsis of the job in as few words as possible.

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.

PRINCIPAL DUTIES AND ESSENTIAL FUNCTIONS:

This section should list up to 10 principal tasks and functions that are considered to be fundamental to the position, establishing expectations for the job to which the individual will be held accountable and are critical to the successful performance of the job. Duties that the employee must be able to perform with or without reasonable accommodation must be included in this section.

Check if this is an essential function of the job

Advanced Machinery Operation & Process Control

• 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.

Quality, Documentation and Compliance

• 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.

Production Performance and Systems Use

• 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.

Troubleshooting & Equipment Optimization

• 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.

Safety & Environmental Compliance

• 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.

Process Improvement & Maintenance

• 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).

Training & Technical Leadership

• 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.

Visual Factory & 5S

• 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.

Employee Ownership Behaviors

• 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.

Communication & Collaboration

• 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

Additional REQUIRED Qualifications/Skills : Please write clearly and concisely any additional qualifications/skills that are required to perform the job competently. Note: If a certain qualification/skill is required for the job, candidates who do not meet that requirement will not be considered for the position.

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.

Additional PREFERRED Qualifications/Skills : Please write clearly and concisely any additional qualifications/skills that are preferred to perform the job.

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.

Page Break

Please complete the sections below by placing an X in the appropriate column based on the following definitions:

Rare=

Rarely (1 time/week)

Cont=

Continually (5-8 hrs/shift)

Occ=

Occasionally (Up to 2 hrs/shift)

NA=

Not applicable (activity not performed)

Freq=

Frequently (2-5 hrs/shift)

PHYSICAL ACTIVITIES

Essential

Activity?

Rare

Occ

Freq

Cont

NA

Describe any job duty
which requires repetition
or a unique application
of the activity .

Sitting

Stationary standing

Walking

Ability to be mobile

Bending

Twisting (knees/waist/neck)

Squatting

Kneeling/crawling

Turning/Pivoting

Climbing

Balancing

Reaching

Overhead/above shoulder

Extending (across desk)

Hand Movement

Handling/fingering/keying

Precision Work

Typing

Writing

Grasping

Pinching

Fine Manipulating

Pushing/Pulling

Pulling up and/or repositioning rolls and materials weighing up to 100 lbs without assistance

Pulling up and/or repositioning rolls and materials weighing up to 450 lbs without assistance

Pushing a rolls and materials weighing up to 250 lbs without assistance

Typical weight (check appropriate weight in lbs):

1-10 11-20 21-30 31-40 41-60 61-80 81-100 >100

Maximum weight (check appropriate weight in lbs):

1-10 11-20 21-30 31-40 41-60 61-80 81-100 >100

Lifting/Carrying

Typical weight (check appropriate weight in lbs):

1-10 11-20 21-30 31-40 41-60 61-80 81-100 >100

Maximum weight (check appropriate weight in lbs):

1-10 11-20 21-30 31-40 41-60 61-80 81-100 >100

Other physical activities not listed:

Please complete the sections below by placing an X in the appropriate column based on the following definitions:

• Essential Function : Check this box if this activity is necessary to perform the primary duties of the job
• Marginal Function : Check this box if the activity is performed on the job but is not essential to the job
• Not Applicable: Check this box if this activity does not occur on the job

SENSORY ACTIVITIES

Essential Function

Marginal Function

Not Applicable

Visual acuity

Close work (paperwork, visual examination)

Color discrimination

Visual monotony

Visual clarity > 20 feet

Visual clarity

Sensory Discrimination

Hot/Cold

Sharp/Dull

Smell

Auditory

Hearing in person

Monitoring Equipment

Hearing on telephone

Background Noise

Speaking

Talking in person

Talking on telephone

MENTAL ACTIVITIES

Essential Function

Marginal Function

Not Applicable

Reasoning/Understanding

Ability to follow directions

Ability to adhere to assigned work schedule

Ability to multitask

Ability to maintain consistent workflow and/or attention to detail

Other mental activities not listed:

ENVIRONMENTAL FACTORS

There is no substantial exposure to adverse environmental conditions

There is potential exposure to adverse environmental conditions.

If this box is checked, please complete section below .

Please complete the sections below by placing an X in the appropriate column based on the following definitions:

Rare=

Rarely (1 time/week)

Cont=

Continually (5-8 hrs/shift)

Occ=

Occasionally (Up to 2 hrs/shift)

NA=

Not applicable (activity not performed)

Freq=

Frequently (2-5 hrs/shift)

Work Environment

Essential

Activity?

Rare

Occ

Freq

Cont

NA

Describe any job duty
which requires repetition
or a unique application
of the activity.

Working Alone

Working with Customer/public contact

Working in confined spaces

Working on slippery or uneven surfaces

Working at heights (such as scaffolding/ladders)

Operates equipment, vehicles or tools

Exposures

Specify Source

Example: Cleaning materials

Exposure to dust, gas, fumes, steam, chemicals

Exposure to infectious disease and/or airborne pathogens

Other environmental factors not listed

DISCLAIMER

The above information provided in this job description has been designed to indicate the general nature and level of work performed by employees within this job classification. It is not designed to contain or be interpreted as a comprehensive inventory of all duties, responsibilities, and qualifications of employees assigned to this job.

APPROVALS

Approval by Manager

Date