Lead Press Operator

Lead Press Operator – Goss Community Press

Department: Web Press / Coldset
Reports To: Production Plant Manager / Operations Manager
Classification: Full-Time, Hourly
Level: Lead Operator / Senior Press Operator

Position Summary

The Lead Goss Community Press Operator is responsible for the safe, efficient, and high-quality operation of the Goss Community coldset web press and SSC folder. This position serves as the lead operator for the press crew and is accountable for press setup, production, print quality, registration, folder performance, waste control, troubleshooting, and completion of scheduled work.

The Lead Operator is expected to take ownership of the press during the assigned shift, direct and train other pressroom employees, communicate production issues promptly, and continuously work to improve productivity, quality, safety, and equipment reliability.

Essential Duties and Responsibilities

Press Operation & Setup

• Lead setup and operation of the Goss Community coldset web press and SSC folder.

• Review job tickets, production specifications, press layouts, pagination, paper requirements, ink requirements, and finishing instructions before production.

• Set up press units, web leads, ink systems, registration, folder, cutoff, slitter, former, and delivery systems as required.

• Perform press make-ready efficiently and prepare the press for production according to job specifications.

• Establish proper ink/water balance and maintain consistent density and print quality throughout the run.

• Maintain proper web tension and registration throughout production.

• Set and monitor cutoff, fold, perforation, slitting, and delivery requirements.

• Perform roll changes and web-ups safely and efficiently.

• Verify correct page sequence, orientation, signatures, and pagination before releasing the job for full production.

Quality Control

The Lead Operator is the primary quality-control person for the press during production.

Responsibilities include:

• Approve startup copies before increasing to production speed.

• Monitor color, registration, cutoff, fold, page position, ink density, scumming, toning, doubling, slur, and other print defects.

• Compare production copies against approved proofs or customer specifications.

• Pull and inspect samples throughout the run.

• Stop or slow the press when product quality falls outside acceptable standards.

• Identify the cause of quality problems and make appropriate corrections.

• Document significant quality issues and corrective actions.

• Prevent knowingly defective product from proceeding to finishing, mailing, or shipping.

Productivity & Waste Control

• Operate the press at the highest practical production speed while maintaining quality and safety.

• Minimize make-ready time, startup waste, running waste, roll-change waste, and unnecessary downtime.

• Monitor paper consumption against estimated and expected usage.

• Accurately document spoilage and the reasons for excessive waste.

• Identify recurring causes of waste and recommend corrective actions.

• Work toward company production and waste standards.

• Accurately report press time, setup time, run time, downtime, quantities, waste, and materials used.

Crew Leadership

The Lead Operator is responsible for directing the press crew during the shift.

• Assign work to press operators, helpers, and roll tenders.

• Clearly communicate job requirements and production expectations.

• Coordinate crew activities during make-ready, web-up, roll changes, production, cleanup, and maintenance.

• Maintain an organized and professional pressroom.

• Train developing operators in proper press operation and procedures.

• Provide constructive coaching when procedures or quality standards are not being followed.

• Help employees develop toward higher operator skill levels.

• Lead by example in attendance, safety, quality, productivity, communication, and teamwork.

• Immediately communicate significant employee, equipment, safety, quality, or production concerns to management.

Troubleshooting

Must be capable of independently diagnosing common press and folder problems, including:

• Web tension problems

• Web breaks

• Registration problems

• Ink/water balance

• Color variation

• Toning and scumming

• Doubling or slurring

• Roller and blanket issues

• Cutoff problems

• Fold problems

• Wrinkles

• Paper tracking problems

• Folder jams

• Delivery problems

• Basic mechanical, pneumatic, electrical, and control-related press issues

The Lead Operator is expected to determine whether an issue can safely be corrected by the press crew or requires maintenance support.

Maintenance & Equipment Care

• Perform required operator-level preventive maintenance.

• Inspect the press before and during production for abnormal wear, leaks, noises, vibration, or other developing problems.

• Maintain proper lubrication according to established schedules.

• Inspect rollers, blankets, cylinders, bearings, gears, guards, air systems, and other critical components.

• Keep press units, folder, work areas, and surrounding floors clean and organized.

• Complete maintenance requests when repairs are required.

• Communicate equipment problems before they result in major downtime whenever possible.

• Assist maintenance personnel with troubleshooting and repairs when appropriate.

• Participate in scheduled preventive-maintenance activities.

Safety Responsibilities

• Follow all company safety procedures and OSHA requirements.

• Enforce lockout/tagout requirements.

• Ensure machine guards and safety devices remain operational and in place.

• Maintain safe procedures around rotating equipment, nip points, moving webs, roll handling, and press components.

• Immediately report unsafe conditions, near misses, injuries, and equipment hazards.

• Stop production when an immediate safety hazard exists.

• Ensure crew members use required personal protective equipment.

Production Communication

The Lead Operator must communicate effectively with Prepress, Production Management, Bindery, Shipping, Maintenance, and other departments.

Before beginning a job, the Lead Operator should confirm that:

• Correct plates are available.

• Correct paper is staged.

• Correct ink and materials are available.

• Job specifications are understood.

• Finishing requirements are understood.

• Required quantities and overs are confirmed.

• Special customer requirements are identified.

Production problems that could affect delivery, quantity, quality, or cost must be reported promptly.

Required Qualifications

• Strong experience operating Goss Community or comparable coldset web press equipment.

• Demonstrated ability to independently set up and operate a multi-unit web press.

• Strong understanding of coldset offset printing.

• Strong understanding of press registration, ink/water balance, web tension, cutoff, and folding.

• Experience operating and troubleshooting an SSC or comparable web press folder.

• Ability to read and understand job tickets, press layouts, proofs, and production specifications.

• Strong mechanical aptitude.

• Ability to diagnose press and print-quality problems.

• Ability to lead and train pressroom employees.

• Strong communication and organizational skills.

• Ability to accurately document production information.

• Commitment to safety, quality, productivity, and continuous improvement.

Lead Operator Performance Expectations

The Lead Operator will be evaluated on:

Safety – Safe operation of the press and leadership of the crew.

Quality – Consistent production that meets customer and company standards.

Waste – Control of startup, running, and paper waste.

Productivity – Efficient make-ready, press speed, and completion of scheduled work.

Downtime – Ability to prevent, troubleshoot, communicate, and reduce avoidable downtime.

Maintenance – Proper equipment care and completion of operator preventive maintenance.

Leadership – Ability to direct, train, communicate with, and develop the press crew.

Documentation – Accurate reporting of time, materials, quantities, waste, downtime, and production issues.

Reliability – Consistent attendance, preparedness, and ownership of scheduled production.

Authority of the Lead Operator

The Lead Press Operator has the authority and responsibility to:

• Stop the press for unsafe conditions.

• Stop or slow production when quality is unacceptable.

• Direct press crew activities during the shift.

• Require established operating and safety procedures to be followed.

• Request maintenance assistance when necessary.

• Escalate production, quality, personnel, or equipment issues to management.

The Lead Operator is expected to exercise this authority professionally and communicate significant production decisions to management.

Physical Requirements

• Ability to stand and walk for extended periods.

• Ability to bend, reach, climb, push, pull, and work around industrial printing equipment.

• Ability to lift and handle materials consistent with pressroom operations.

• Ability to work safely around moving machinery, paper rolls, ink, solvents, noise, and other normal pressroom conditions.

• Ability to work overtime when production requirements reasonably require it.

Overall Standard

The Lead Goss Community Press Operator is expected to own the performance of the press during the assigned shift .

Success in this position means producing quality work safely, on time, and with controlled waste while maintaining the equipment and developing a capable press crew.