Description
The Packaging Machine Operator plays a pivotal role in ensuring the continuous and efficient functioning of the packaging line in compliance with Integrated Packaging Solutions (IPS) standards. This position is integral to maintaining product quality, optimizing machinery performance, and ensuring safety regulations are met. Operators will be responsible for various tasks, including machine operation, maintenance, and quality control, all while adhering to production targets.
Responsibilities
1. Machine Allocation and Utilization
- Correct Allocation: Allocate packing machines based on production splits to ensure optimal utilization. This includes assessing the needs of the production line and adjusting machine assignments accordingly.
- Changeovers: Perform changeovers for bag makers and weighers as required, ensuring a seamless transition that minimizes downtime.
- Material Availability: Monitor and ensure that sufficient materials (e.g., bags, films, labels) are available for production needs to prevent interruptions.
2. Efficiency Maintenance
- Performance Monitoring: Maintain an efficiency level of at least 85% for all packaging machines. This involves closely monitoring operations and implementing adjustments as necessary to maximize output.
- Optimal Machine Operation: Ensure that machines are running at optimal settings to reduce delays and improve overall productivity.
3. Waste Minimization
- Film Waste Control: Strive to minimize film waste to below 1.0%. This requires careful monitoring of material usage and quick adjustments to processes as needed to prevent excess waste.
4. Quality Control
- Audits and Reporting: Conduct regular quality control audits of the packaging process. Complete relevant reports that document findings, issues, and corrective actions taken.
- Quality Standards Compliance: Ensure that all packaged products meet established quality standards, and take immediate action if deviations are detected.
5. Equipment Maintenance
- Routine Monitoring: Continuously monitor packaging equipment to ensure proper functioning. Notify engineering of any maintenance needs or equipment malfunctions.
- Minor Repairs: Carry out minor repairs and adjustments on packaging equipment to maintain operational efficiency and minimize downtime.
6. Compliance and Documentation
- SOC Compliance: Ensure 100% compliance with Standard Operating Procedures (SOC) sheets, including proper documentation and reporting practices.
- Data Input: Accurately input production data and manage allergen changeovers, ensuring all information is recorded in a timely manner during both starting and shutting down processes.
7. Housekeeping and Safety Standards
- Good Housekeeping Practices: Maintain a clean and organized workspace according to AIB (American Institute of Baking) standards. This includes proper storage of materials and cleanliness of machinery.
- Safety Compliance: Adhere to safety regulations to ensure a safe working environment for all team members. Report any safety concerns immediately.
8. Audits and System Procedures
- IPS Audits: Conduct IPS audits as per established systems procedures to ensure compliance with company standards and identify areas for improvement.
- Line Balancing: Maintain balance across production lines to ensure that workload is evenly distributed and production goals are met.
9. Total Productive Maintenance (TPM)
- Implementation of TPM-AM: Ensure that the Total Productive Maintenance – Autonomous Maintenance (TPM-AM) pillar is effectively implemented on assigned machines. This includes training operators on maintenance practices.
- CLTI Compliance: Carry out Cleaning, Lubrication, Tightening, and Inspection (CLTI) for machinery as per the established frequency to ensure longevity and reliability of equipment.
10. Additional Responsibilities
- Flexible Role: Be prepared to undertake other accountabilities and tasks assigned by management as needed, contributing to the overall success of the production team.
Decision-Making Authority
The Packaging Machine Operator has the complete freedom to make decisions and take necessary actions to achieve desired business results on bag makers, with or without reference to the Front Line Manager (FLM). This includes operational decisions that can significantly impact production efficiency and product quality.
Job Challenges
- Varying Product Density: Operators must adapt to products of varying densities, which can affect the packaging process.
- Frequent Plan Changes: Rapid changes in production plans can challenge the operator’s ability to maintain efficiency and quality.
- High-Speed Machines: The operation of high-speed machines with sophisticated controls requires constant attention and quick reflexes.
- Aging Equipment: Managing aging packaging equipment necessitates a proactive approach to maintenance and repairs.
- Balancing Production and Safety: Operators must navigate the complexities of meeting production requirements while adhering to food safety and occupational safety standards.
Qualifications
Knowledge/Skills
- Educational Background: A diploma in Mechanical or Electronics is required. Relevant tertiary qualifications will be an advantage.
Experience
- Industry Experience: A minimum of 3 years of experience operating packing machines in a manufacturing environment is essential.
Competencies
- Analytical Thinking: Ability to assess processes, identify issues, and implement effective solutions.
- Drive for Results: Strong focus on achieving production goals and efficiency standards.
- Intellectual Curiosity: Willingness to learn and adapt to new processes, technologies, and industry best practices.
- Integrity: Commitment to ethical practices and adherence to company policies and standards.
- Developing Others: Capability to mentor and train junior team members, fostering a collaborative and skilled workforce.
Average Salary
- National Average: As of 2024, the average salary for Packaging Machine Operators ranges from $35,000 to $55,000 per year.
- Hourly Rate: This translates to approximately $16 to $26 per hour.
Factors Influencing Salary
- Location: Salaries tend to be higher in urban areas or regions with a high cost of living. For example:
- California: $40,000 – $60,000
- New York: $38,000 – $58,000
- Texas: $35,000 – $50,000
- Experience: Operators with more experience can command higher wages. Entry-level positions may start at the lower end of the scale, while those with several years in the field might earn closer to $60,000 or more.
Benefits
In addition to salary, many Packaging Machine Operators receive benefits, which can include:
- Health insurance
- Retirement plans
- Paid time off
- Overtime pay (which can significantly increase annual earnings)