Skilled Machine Operator - Flame Laminator

Job Description

Job Description

We are seeking an advanced Skilled Machinist – Flame Lamination to join our manufacturing team. This role requires high-level technical expertise in machining processes and flame lamination operations to produce high-quality bonded components. The successful candidate will leverage strong mechanical aptitude, blueprint reading skills, and thermal process controls to operate specialized equipment, troubleshoot process variances, and maintain strict product standards. Additionally, this position acts as a subject matter expert, providing technical coaching and guidance to junior operators. This role reports directly to the General Manager.

Key Responsibilities

Flame Lamination & Technical Machine Operation

• Precision Parameter Setup: Set, calibrate, and adjust critical lamination parameters, including roller pressure, nip roller height, feed speeds, and web line tensions.
• Flame & Thermal Calibration: Regulate gas flow, ignition systems, and burner height to maintain precise flame temperatures required for optimal surface activation of thermoplastic foams without scorching or degrading materials.
• Substrate Alignment & Web Handling: Thread, align, synchronize foam, and fabric rolls through machine guide systems, controlling tension to eliminate wrinkling, stretching, or edge misalignment.
• Mechanical Maintenance: Perform routine mechanical adjustments and preventive maintenance on rollers, drive systems, conveyors, burner assemblies, and auxiliary machinery to ensure continuous operational readiness.

Process Troubleshooting & Quality Assurance

• Technical Calculations: Compute material usage, yield percentages, speed-to-temperature ratios, and burner positioning based on job specifications and shop orders.
• Root-Cause Analysis: Swiftly diagnose and resolve bonding defects such as delamination, foam degradation, uneven burn profiles, or non-uniform flame distribution.
• Quality Inspection: Perform continuous visual and physical bond-strength checks using precision tools (calipers, force gauges, scales) to verify compliance with engineering blueprints and QMS standards (ISO 9001/13485).
• Documentation: Maintain accurate, real-time production logs capturing heat settings, gas pressures, feed rates, material lot tracking, and scrap counts.

Workflow Leadership & Technical Coaching

• Mentorship: Serve as the primary subject matter expert on the floor, training junior operators on machine loading/unloading, setup procedures, and adhesive/bond quality checks.
• Performance Oversight: Monitor line output and team execution, providing real-time technical feedback to ensure safety standards, quality specifications, and production targets are consistently met.

Required Qualifications

• Education: High School Diploma or equivalent; Trade school certification or Associate degree in Mechanical Technology or Machining preferred.
• Experience: 3–5+ years of experience operating complex technical machinery, flame lamination lines, or web conversion systems in a manufacturing environment.
• Technical Aptitude: Proven expertise in blueprint reading, precision measurement tools, mechanical setups, and basic machine maintenance.
• Mathematical Proficiency: Strong shop math skills for calculating burner heights, feed adjustments, percentages, and unit conversions.
• Communication: Ability to effectively train, mentor, and communicate process instructions to team members.

Preferred Qualifications

• Hands-on experience operating within an ISO 9001 or ISO 13485 certified facility.
• Experience with automated web-tension systems and gas burner safety interlocks.
• Prior experience in a Lean Manufacturing / 5S environment.
• Forklift certification or overhead crane training for heavy roll handling.

Physical & Safety Requirements

Production Floor Environment (80% – 90% of Time)

• Flame & Gas Safety: Strict adherence to open-flame safety protocols, including daily inspections of flame arresters, gas shutoff valves, ventilation hoods, and emergency stops.
• Physical Demands: Capacity to stand for extended shifts (8–10+ hours), bend, stoop, and regularly lift/maneuver material rolls weighing 50–60 lbs .
• Environmental Conditions: Exposure to high-heat equipment, open flames, industrial noise, and combustion byproducts.
• Personal Protective Equipment (PPE): Required use of safety glasses, steel-toe boots, hearing protection, heat-resistant gloves, and flame-resistant clothing as designated.

EEO Statement

Reilly Foam Corporation is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or protected veteran status.

Experienced, Dedicated, Trusted
For over 50 years, Reilly Foam Corporation has specialized in engineered foams for thousands of consumer, medical, and industrial applications. With four locations across the United States, 450,000 square feet of manufacturing space, state of the art equipment, and modern fabrication technology, the possibilities are endless! Reilly Foam’s knowledgeable and experienced staff of foam experts excel at every aspect of foam fabrication, processing, and creative solutions for any and every application. Whether the job is large or small, customer satisfaction is always our most important goal!

Company Description

Experienced, Dedicated, Trusted\r\nFor over 50 years, Reilly Foam Corporation has specialized in engineered foams for thousands of consumer, medical, and industrial applications. With four locations across the United States, 450,000 square feet of manufacturing space, state of the art equipment, and modern fabrication technology, the possibilities are endless! Reilly Foam’s knowledgeable and experienced staff of foam experts excel at every aspect of foam fabrication, processing, and creative solutions for any and every application. Whether the job is large or small, customer satisfaction is always our most important goal!