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Key Responsibilities and Required Skills for Operator

💰 $ - $

ManufacturingOperationsProduction

🎯 Role Definition

The Operator is responsible for safely and efficiently running production equipment, monitoring process parameters, performing basic troubleshooting and preventive maintenance, and ensuring products meet quality standards. This role requires strong attention to detail, adherence to safety and regulatory requirements, and the ability to follow standard operating procedures (SOPs). Operators work closely with maintenance, quality, and production teams to maximize uptime, minimize defects, and support continuous improvement initiatives.

Key target keywords: machine operator, production operator, plant operator, process control, safety compliance, quality assurance, SOP, PLC, lean manufacturing.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Production Associate / Assembly Technician
  • Warehouse Associate / Material Handler
  • Maintenance Helper / Apprentice

Advancement To:

  • Senior Operator / Lead Operator
  • Shift Supervisor / Production Supervisor
  • Process Technician / Maintenance Technician

Lateral Moves:

  • Quality Technician / Inspector
  • Inventory or Logistics Coordinator

Core Responsibilities

Primary Functions

  • Operate and monitor production equipment and machinery (e.g., CNC machines, injection molders, conveyors, presses, mixers) to meet daily production schedules while ensuring safety and quality standards are maintained.
  • Set up machines, change tooling, load materials, and adjust process parameters in accordance with work orders, engineering instructions, and Standard Operating Procedures (SOPs) to achieve specified cycle times and tolerances.
  • Monitor process variables (temperature, pressure, speed, flow, weight) using on-board controls or SCADA/PLC systems, and make real-time adjustments to maintain product consistency and reduce waste.
  • Perform in-process quality checks, measure key dimensions, complete inspection records, and escalate non-conforming product to Quality Assurance while documenting corrective actions.
  • Execute first-line troubleshooting for mechanical, electrical, and process issues, isolating causes and performing corrective actions within operator scope to minimize downtime.
  • Conduct routine preventive maintenance tasks (cleaning, lubrication, belt changes, filter replacement) and complete maintenance logs and TPM checklists; coordinate with maintenance team for complex repairs.
  • Follow lockout/tagout (LOTO), confined space, and other site-specific safety procedures during set-up, maintenance, and cleaning activities to protect personnel and equipment.
  • Safely handle, store, and transport raw materials, finished goods, and hazardous substances using appropriate PPE, material handling equipment (forklift, pallet jack), and hazardous communication (HazCom) procedures.
  • Accurately complete production documentation, batch records, digital logs, and enterprise systems (e.g., MES, SAP, Oracle) to ensure traceability, compliance, and inventory accuracy.
  • Participate in pre-shift briefings and handovers; communicate process status, quality issues, and safety concerns to incoming shifts and supervisors to maintain continuity.
  • Implement and support continuous improvement and lean manufacturing initiatives (5S, Kaizen, value stream mapping) by identifying bottlenecks, suggesting improvements, and participating in kaizen events.
  • Ensure finished goods are packaged, labeled, and staged per customer specifications and regulatory requirements (e.g., ISO, GMP, FDA), and assist warehouse with staging and shipping when required.
  • Maintain clean, organized workstations and adhere to 5S standards to improve efficiency, reduce defects, and enhance workplace safety.
  • Train and mentor new operators on equipment operation, safety policies, quality expectations, and SOPs, documenting competency checks and training records.
  • Execute material changeovers and line changeovers with minimal scrap by planning and coordinating resources, updating setup checklists, and verifying first-piece conformity.
  • Collaborate with Quality and Engineering to support root cause analysis (RCA) and corrective/preventive action (CAPA) plans for recurring defects or equipment failures.
  • Record and report safety incidents, near-misses, and process deviations immediately; participate in incident investigations and follow through on corrective actions.
  • Maintain inventory of process consumables, tooling, and spare parts; submit replenishment requests and support cycle counts to prevent production interruptions.
  • Adhere to environmental, health, and safety (EHS) regulations and company policies; participate in drills, audits, and safety meetings to foster a culture of risk awareness.
  • Utilize hand tools, measuring instruments (calipers, micrometers), and test equipment to verify machine setup and product quality throughout production runs.
  • Work flexible shifts (day, night, rotating) and overtime as required to meet production demands while maintaining consistent performance and reliability.
  • Communicate effectively with cross-functional teams (maintenance, engineering, quality, supply chain) to coordinate repairs, process changes, and production priorities.
  • Support sample collection, documentation, and shipping for customer or regulatory testing when required, ensuring chain-of-custody and correct labeling.
  • Maintain confidentiality of proprietary processes and protect intellectual property by following company information security and access policies.

Secondary Functions

  • Assist in small-scale process improvement projects and contribute operator-level insights during process design and layout changes.
  • Support onboarding and training programs by providing practical demonstrations and operator perspectives for new equipment or procedures.
  • Help prepare shift summaries and production performance reports for daily management review and continuous improvement tracking.
  • Participate in cross-training to provide flexible coverage across multiple machines or lines during peak periods or absences.
  • Provide input to engineering on manufacturability issues, ergonomic improvements, and tool design to reduce cycle time and improve worker safety.

Required Skills & Competencies

Hard Skills (Technical)

  • Operation of production equipment such as CNC machines, injection molding machines, packaging lines, extruders, presses, mixers, or automated assembly systems.
  • Basic PLC and HMI operation and the ability to interpret control screens and alarms (Siemens, Allen-Bradley, Schneider).
  • Understanding of SCADA/MES systems and experience recording production data and batch records in electronic systems.
  • Familiarity with quality systems and standards: ISO 9001, GMP, FDA regulations, and experience performing in-process inspections and statistical process control (SPC).
  • Proficient with hand tools and precision measuring instruments (calipers, micrometers, gauges) to verify part conformity and setup.
  • Knowledge of lockout/tagout (LOTO), confined space entry, hazardous energy control, and other EHS protocols.
  • Experience with preventive maintenance tasks, basic mechanical troubleshooting, and reading mechanical/electrical schematics.
  • Material handling skills including safe forklift operation (powered pallet jack, sit-down forklifts) and understanding of proper storage and labeling procedures.
  • Competence in interpreting engineering drawings, work orders, and specifications for correct part setup and verification.
  • Working knowledge of lean manufacturing tools: 5S, Kaizen, SMED, and waste reduction techniques to support productivity improvements.
  • Comfortable using enterprise software (SAP, Oracle, MES) for production reporting, work orders, and inventory transactions.
  • Basic math and computer skills for setting production parameters, calculating yields, and completing digital records.

Soft Skills

  • Strong attention to detail and a commitment to producing defect-free work while following SOPs and quality standards.
  • Clear verbal and written communication skills for shift handovers, reporting quality issues, and coordinating with cross-functional teams.
  • Problem-solving mindset with the ability to diagnose basic equipment issues and escalate appropriately.
  • Team player attitude and willingness to support colleagues during peak production or tight deadlines.
  • Time management and ability to prioritize tasks in a fast-paced manufacturing environment.
  • Adaptability to shift schedules, changing production priorities, and continuous improvement initiatives.
  • Accountability and ownership for meeting production targets, safety standards, and quality expectations.
  • Observational skills to recognize abnormal conditions, near misses, and potential safety hazards.
  • Coaching and mentoring ability to train junior operators and ensure consistent performance across shifts.
  • Initiative to suggest process improvements and participate actively in kaizen and lean events.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or equivalent (GED); vocational certification or technical school preferred.

Preferred Education:

  • Associate degree or certificate in Mechanical Technology, Manufacturing, Industrial Maintenance, or a related technical discipline.
  • Additional certifications such as Forklift Operator, OSHA 10/30, PLC programming basics, or Six Sigma Yellow/Green Belt are advantageous.

Relevant Fields of Study:

  • Manufacturing Technology
  • Mechanical Engineering Technology
  • Industrial Maintenance
  • Electrical Technology
  • Process Operations

Experience Requirements

Typical Experience Range:

  • 1–5 years of direct experience in a manufacturing, processing, or warehouse operator role. Entry-level roles may accept less with relevant training.

Preferred:

  • 3+ years operating production equipment with demonstrated experience in process control, preventive maintenance, quality checks, and safety compliance. Prior experience with PLCs, MES systems, or regulated environments (GMP/FDA) is strongly preferred.
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