Key Responsibilities and Required Skills for Gravure Operator Assistant

🎯 Role Definition

The Gravure Operator Assistant is a foundational role within our high-speed printing operations, serving as the primary support for the Lead Gravure Operator. This position is critical to ensuring the efficient setup, operation, and maintenance of sophisticated rotogravure printing presses. The Assistant is instrumental in maintaining production flow, upholding stringent quality standards, and ensuring a safe working environment. This hands-on role requires a keen mechanical aptitude, meticulous attention to detail, and the ability to work collaboratively in a fast-paced production setting. Success in this position is a direct contributor to minimizing press downtime, reducing material waste, and consistently delivering high-quality printed products that meet or exceed client expectations.

📈 Career Progression

Typical Career Path

Entry Point From:

Production Associate or General Laborer
Warehouse or Material Handler
Machine Operator Trainee

Advancement To:

Gravure Press Operator (Second Pressman)
Lead Gravure Press Operator (First Pressman)
Production Shift Supervisor

Lateral Moves:

Flexographic Press Assistant
Quality Control Inspector (Printing)

Core Responsibilities

Primary Functions

Actively assist the Lead Operator with the complete setup and changeover of rotogravure presses, including the installation and alignment of engraved printing cylinders and doctor blades.
Precisely mix and prepare inks according to detailed job specifications and color matching formulas, diligently monitoring and adjusting viscosity throughout the production run.
Safely and efficiently load massive rolls of substrate (such as film, paper, or foil) onto the press unwinders and unload finished printed rolls from the rewinders using hoists or other material handling equipment.
Perform rigorous and routine cleaning of press components, including ink pans, rollers, doctor blades, and printing decks, to prevent contamination and ensure optimal print quality.
Prepare and stage all necessary raw materials for upcoming jobs, including retrieving correct cylinders, inks, solvents, and substrates to minimize changeover time.
Conduct continuous visual inspections of the printed web during the press run to identify and report any print defects, such as hazing, streaks, color variations, or misregistration.
Provide hands-on support during the webbing of the press, skillfully guiding the substrate through the complex path of rollers and stations.
Accurately mount and secure printing cylinders into the press, ensuring proper tension and alignment as directed by the Lead Operator.
Assist in troubleshooting minor press malfunctions and operational issues, working alongside the operator to identify root causes and implement corrective actions swiftly.
Diligently maintain a clean, organized, and safe work area around the press, adhering to 5S principles and company-wide housekeeping standards.
Operate material handling equipment, such as pallet jacks and forklifts, to transport raw materials and finished goods to and from the press area.
Meticulously document production data, including material usage, run times, waste amounts, and quality control checks, in the manufacturing execution system (MES).
Execute basic preventative maintenance tasks as scheduled, such as lubrication, parts inspection, and filter changes, to contribute to machine longevity and reliability.
Properly handle, label, and dispose of hazardous and non-hazardous waste materials, including used solvents, inks, and cleaning rags, in compliance with all environmental and safety regulations.
Maintain clear and constant communication with the Lead Operator, quality control personnel, and shift supervisors regarding job status, material needs, and potential issues.
Prepare finished rolls for the next stage of production or for shipment by properly wrapping, labeling, and palletizing them according to customer and internal specifications.
Retrieve specified engraved cylinders from the storage library and carefully inspect them for any damage or wear before mounting them on the press.
Assist the operator in setting and adjusting the inline slitting and rewinding units to ensure finished rolls meet precise width and tension requirements.
Perform quality control tests using specialized equipment, such as a viscometer for ink and a densitometer or spectrophotometer for color accuracy.
Proactively monitor all safety guards and emergency stops on the equipment, ensuring they are functional and properly in place before and during operation.

Secondary Functions

Support the production team in managing inventory levels for press-side consumables like inks, solvents, and cleaning supplies.
Actively participate in continuous improvement projects and Kaizen events aimed at enhancing safety, quality, and press efficiency.
Collaborate with the maintenance department by providing detailed information about machine performance and potential mechanical issues.
Participate in daily team meetings, safety briefings, and training sessions to stay current on operational priorities and best practices.

Required Skills & Competencies

Hard Skills (Technical)

Basic Machine Operation: Ability to learn and assist in the operation of complex industrial machinery.
Ink Mixing & Color Matching: Foundational understanding of mixing inks to achieve specific color and viscosity targets.
Material Handling: Experience operating forklifts, electric pallet jacks, and overhead hoists safely.
Quality Control Inspection: Skill in visually identifying common print defects and using basic measurement tools.
Mechanical Aptitude: Competency in using hand and power tools for basic machine adjustments and maintenance.
Measurement & Math Skills: Ability to perform basic arithmetic, conversions, and accurately read a tape measure.
Computer Data Entry: Proficiency in using a computer to log production data into company software or MES.
Reading Job Orders: Ability to read and interpret technical information from job tickets and specification sheets.
Safety Protocol Adherence: Knowledge of manufacturing safety standards, including Lockout/Tagout (LOTO) procedures.
Cylinder & Plate Mounting: Experience or demonstrated ability to learn the process of mounting printing cylinders.

Soft Skills

Attention to Detail: Meticulous in monitoring quality and following multi-step procedures without error.
Teamwork & Collaboration: Works effectively with operators and other team members to achieve shared goals.
Strong Work Ethic: Reliable, punctual, and motivated to perform tasks to the best of one's ability.
Problem-Solving: Ability to think critically and assist in resolving operational challenges as they arise.
Verbal Communication: Clearly communicates information, questions, and concerns to the team.
Adaptability: Thrives in a fast-paced environment and can adjust to changing priorities and production schedules.
Sense of Urgency: Understands the importance of minimizing downtime and works efficiently to complete tasks.
Willingness to Learn: Eager to acquire new technical skills and knowledge about the gravure printing process.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED equivalent.

Preferred Education:

Vocational or Technical School Certificate in a related field.

Relevant Fields of Study:

Graphic Communications / Printing Technology
Manufacturing Technology

Experience Requirements

Typical Experience Range:

0-2 years of experience in a manufacturing, production, or industrial environment.

Preferred:

1+ year of direct experience as a Press Helper or Assistant in a printing environment (Gravure, Flexographic, or Offset).
Prior experience working in a role that required strong mechanical aptitude and attention to detail.