Key Responsibilities and Required Skills for Rewind Operator

🎯 Role Definition

The Rewind Operator is a cornerstone of our production finishing department, playing a vital role in transforming master rolls of material into final products that meet precise customer specifications. This position is entrusted with the setup, operation, and monitoring of sophisticated slitter-rewinder equipment. The operator is the final guardian of quality, ensuring every roll produced adheres to the highest standards of tension, width, and overall integrity. Success in this role directly contributes to plant efficiency, waste reduction, and most importantly, customer satisfaction. It requires a mechanically-inclined individual with a sharp eye for detail and a steadfast commitment to safety and excellence.

📈 Career Progression

Typical Career Path

Entry Point From:

Production Associate or Assistant
Machine Operator Helper
Packaging and Material Handler

Advancement To:

Lead Rewind Operator or Finishing Lead
Production Supervisor or Team Leader
Quality Control Technician or Inspector

Lateral Moves:

Converting Machine Operator (Laminator, Coating)
Maintenance Technician (with additional training)

Core Responsibilities

Primary Functions

Accurately interpret and execute detailed instructions from job dockets, work orders, and production schedules to ensure all specifications are met.
Independently set up and configure slitter-rewinder machinery, including installing the correct core sizes, setting slitting blades to precise widths, and adjusting machine tension and speed.
Safely and skillfully operate the rewinder machine, constantly monitoring the web for defects, print quality, and proper alignment throughout the run.
Conduct rigorous in-process and final quality control checks on finished rolls, utilizing precision measuring instruments to verify roll diameter, width, and label placement.
Efficiently remove finished, slit rolls from the rewind shaft, and carefully package, palletize, and label them according to specific customer and shipping requirements.
Proactively perform routine operator-level maintenance, including cleaning the machine, lubricating moving parts, and inspecting for wear and tear to prevent downtime.
Troubleshoot and resolve common machine-related issues, such as web breaks, tension problems, or blade imperfections, to maintain production flow and minimize scrap.
Master the loading of heavy parent rolls onto the machine's unwind stand using appropriate material handling equipment, ensuring proper alignment and safety.
Diligently and accurately complete all necessary production paperwork, logbooks, and electronic data entry to track output, material usage, and downtime.
Maintain a keen focus on minimizing material waste and scrap by optimizing machine setup, closely monitoring runs, and making immediate adjustments as needed.
Inspect, sharpen, and replace slitter blades as required to ensure a clean, precise cut and prevent defects in the finished product.
Manage and stage all necessary raw materials, such as cores, films, and packaging supplies, for upcoming jobs to ensure seamless production transitions.

Secondary Functions

Uphold and champion all company safety protocols and procedures, including Lockout/Tagout (LOTO), use of Personal Protective Equipment (PPE), and general machine guarding.
Maintain a high standard of housekeeping within the work cell, ensuring the area around the machine is clean, organized, and free of hazards.

Communicate effectively and professionally with shift supervisors, maintenance personnel, and quality assurance teams regarding production status, machine issues, or material defects.

Assist in the training and mentoring of new operators, sharing knowledge of machine operation, quality standards, and safety best practices.
Actively participate in continuous improvement programs, offering suggestions and feedback to enhance safety, quality, and productivity.
Operate material handling equipment, such as pallet jacks and forklifts (if certified), to transport raw materials and finished goods throughout the facility.
Weigh and meticulously record the weight of finished rolls and scrap material for inventory management and production tracking purposes.
Collaborate with the preceding and succeeding shifts to ensure a smooth and informed transition, discussing any ongoing issues or special instructions.

Required Skills & Competencies

Hard Skills (Technical)

Slitter/Rewinder Operation: Demonstrated proficiency in the setup, operation, and basic troubleshooting of web-fed slitter-rewinder or similar converting machinery.
Mechanical Aptitude: Strong ability to understand and work with mechanical systems, including making fine-tuned adjustments and performing basic maintenance.
Precision Measurement: Skill in accurately using and reading measuring tools such as tape measures, rulers, micrometers, and calipers.
Basic Mathematics: Solid understanding of basic math, including fractions and decimals, for calculating measurements and verifying specifications.
Computer Literacy: Competency in using basic computer software and HMI (Human-Machine Interface) panels for data entry and machine control.
Material Handling: Experience safely operating manual pallet jacks and/or powered industrial trucks (forklifts) for moving heavy materials.

Soft Skills

Attention to Detail: An exceptional eye for detail to spot subtle defects, ensure precise measurements, and maintain high-quality standards consistently.
Problem-Solving: The ability to logically identify the root cause of a machine or quality issue and implement an effective solution in a timely manner.
Safety-First Mindset: A deeply ingrained commitment to following safety procedures without exception to protect oneself and fellow team members.
Time Management & Urgency: Excellent organizational skills to manage multiple tasks and prioritize work to meet demanding production deadlines.
Teamwork and Communication: Strong interpersonal skills to collaborate effectively with team members and clearly communicate information across shifts and departments.
Dependability & Work Ethic: A reliable and responsible professional who takes ownership of their work and demonstrates a strong commitment to their role.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or equivalent (GED).

Preferred Education:

Certificate from a vocational or technical school.

Relevant Fields of Study:

Manufacturing Technology
Industrial Mechanics

Experience Requirements

Typical Experience Range: 1-3 years of hands-on experience in a manufacturing environment, preferably as a machine operator.

Preferred: 2+ years of direct, hands-on experience operating a slitter, rewinder, doctor machine, or similar web-handling converting equipment is highly desirable.