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Key Responsibilities and Required Skills for Insert Operator

💰 $32,000 - $55,000

ManufacturingProductionOperationsAssembly

🎯 Role Definition

An Insert Operator is a skilled production professional responsible for accurately placing, securing and verifying inserts (metal, plastic, electronic, or threaded components) into assemblies, molds, or circuit boards using manual and automated insertion equipment. This role focuses on maintaining production flow, ensuring first-pass quality, reducing rework, and supporting continuous improvement initiatives in a manufacturing or electronics assembly environment. Ideal candidates demonstrate strong manual dexterity, process discipline, attention to detail, and familiarity with quality and safety systems (ISO, 5S, ESD).

📈 Career Progression

Typical Career Path

Entry Point From:

  • Production Assembler / General Assembler
  • Machine Operator (CNC, press, or molding)
  • Electronics Assembler or PCB Technician

Advancement To:

  • Lead Insert Operator / Senior Machine Operator
  • Production Supervisor / Team Lead
  • Process Technician or Manufacturing Engineer
  • Quality Engineer / Quality Supervisor

Lateral Moves:

  • Maintenance Technician / Preventive Maintenance
  • Quality Inspector or Quality Technician
  • Tooling or Fixture Specialist

Core Responsibilities

Primary Functions

  • Operate automated and semi-automated insertion machines to place inserts into injection molds, housings, printed circuit boards (PCBs), or mechanical assemblies while consistently meeting cycle time and production targets.
  • Setup and changeover insertion equipment, including loading part feeders, adjusting placement fixtures, changing tooling, and verifying alignment to engineering drawings and work instructions.
  • Accurately position and hand-place inserts in low-volume or specialty assemblies ensuring correct orientation, depth and torque specifications are met to avoid functional failures.
  • Perform in-process inspection of inserted parts using calibrated gauges, calipers, micrometers and visual inspection tools to verify dimensions, seating, and finish against first-article and sampling criteria.
  • Execute standardized work and follow written procedures, routers, and poka-yoke devices to guarantee repeatability and reduce variation across shifts.
  • Monitor machine performance indicators (cycle time, reject rates, downtime) and log production data in MES/ERP systems, shift reports, and SPC charts for traceability and continuous improvement.
  • Detect, diagnose and troubleshoot routine machine faults, jams and misfeeds; perform corrective actions such as clearing jams, resetting sensors and minor adjustments to resume production quickly.
  • Conduct quality containment and segregation of non-conforming parts; document defects, tag material, and initiate corrective action requests to minimize customer impact.
  • Apply ESD controls, contamination prevention protocols and clean-room handling procedures when working with static-sensitive or hygiene-critical components.
  • Perform basic preventative maintenance tasks including cleaning, inspection, lubrication, and replacement of consumable tooling to maintain uptime and part quality.
  • Participate in first article inspections (FAI) and production validations when new inserts, parts, or processes are introduced to verify fit, function and manufacturability.
  • Read and interpret engineering drawings, bill of materials (BOM), and work instructions to ensure the correct insert type, orientation, and torque specifications are applied.
  • Calibrate and validate measurement and inspection equipment per schedule or when discrepancies are identified; escalate to quality/metrology for out-of-tolerance conditions.
  • Support high-mix, low-volume setups by preparing kitting, labeling parts, and verifying inventory counts to prevent production interruptions.
  • Execute torqueing or press-fitting operations to specification, including monitoring torque wrenches, pneumatic presses or ultrasonic insertion equipment to achieve consistent seating forces and avoid damage.
  • Train and mentor new operators on standard work, quality requirements and safe machine operation; provide hands-on coaching to raise overall team capability.
  • Implement and suggest process improvements, 5S visual controls, and waste reduction ideas to improve throughput, yield and operator ergonomics.
  • Work cross-functionally with manufacturing engineering, quality, and supply chain to resolve supplier issues, tooling changes, or part revisions that affect insertion processes.
  • Maintain a clean, organized work area and follow all plant safety policies, machine lockout/tagout (LOTO) procedures and PPE requirements to prevent incidents.
  • Track and help investigate yield, scrap and customer complaints associated with insert failures, contributing data and root cause evidence to corrective action plans.
  • Support audit readiness for internal and external audits by keeping accurate records, batch documentation, and by demonstrating compliant processes to auditors.

Secondary Functions

  • Support ad-hoc data requests and exploratory data analysis.
  • Contribute to the organization's data strategy and roadmap.
  • Collaborate with business units to translate data needs into engineering requirements.
  • Participate in sprint planning and agile ceremonies within the data engineering team.
  • Assist in continuous improvement projects and Kaizen events focused on takt time reduction, defect elimination and cycle time improvements.
  • Help source and validate new insertion tooling or feeder solutions for improved reliability.
  • Promote cross-training across adjacent work cells to increase team flexibility and coverage.
  • Participate in safety committees and contribute to safety observations and corrective actions.

Required Skills & Competencies

Hard Skills (Technical)

  • Hands-on operation of automated insertion equipment, manual insertion tools and semi-automatic presses.
  • Machine setup, changeover and tooling alignment for insert placement and press-fit operations.
  • Proficiency with inspection tools: calipers, micrometers, go/no-go gauges, and optical magnifiers.
  • Basic soldering/wave or hand soldering experience (for PCB insert applications) and understanding of through-hole and SMT processes.
  • Knowledge of ESD controls and safe handling for electrostatic-sensitive devices.
  • Experience using MES/ERP production systems and logging lot/batch traceability data.
  • Familiarity with SPC, first article inspection (FAI), and basic quality control principles and documentation.
  • Ability to read and interpret mechanical and electrical drawings, BOMs, and work instructions.
  • Basic PLC troubleshooting and familiarity with sensors, actuators and pneumatic systems.
  • Preventive maintenance and minor mechanical repair skills (bearing, feeder, fixture replacement).
  • Experience with quality systems such as ISO 9001, AS9100, or equivalent regulated manufacturing environments.
  • Competence with torque tools, press-fit equipment and controlled force insertion devices.
  • Comfortable using digital documentation and standard office tools (Excel, Google Sheets) for production reporting.

Soft Skills

  • Keen attention to detail and high standards for first-pass quality.
  • Strong communication skills—clear, concise shift handoffs and documentation.
  • Problem-solving mindset with the ability to perform root cause analysis and close corrective actions.
  • Team player who works collaboratively with operators, engineers and quality personnel.
  • Time management and organizational skills for high-mix, deadline-driven production.
  • Adaptability and willingness to learn new equipment and processes quickly.
  • Initiative and continuous improvement orientation—proposes and implements efficiency gains.
  • Dependability with strong attendance, punctuality and safety awareness.
  • Customer focus and ownership for meeting delivery and quality expectations.
  • Patience and manual dexterity for repetitive fine-motor tasks under production pressure.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED required.

Preferred Education:

  • Technical certificate, associate degree, or vocational training in Manufacturing Technology, Electronics, Industrial Maintenance or related field preferred.

Relevant Fields of Study:

  • Manufacturing Technology
  • Electrical / Electronics Technology
  • Mechanical Engineering Technology
  • Industrial Maintenance / Mechatronics

Experience Requirements

Typical Experience Range:

  • Entry: 0–2 years in manufacturing or assembly roles.
  • Mid-level: 2–5 years operating insertion equipment or similar production machinery.

Preferred:

  • 2+ years of direct experience with insertion equipment, press-fit processes, or electronics/metal insert assembly.
  • Experience in regulated environments (ISO, AS9100, FDA) or industries with high quality demands (medical devices, aerospace, electronics) is a plus.
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