Utility Operator - Corrugator

Job Description

Job Description

Job Title: Corrugator Wet End Operator

Department: Corrugator

Reports to: Corrugator Supervisor

Location: Sturtevant, WI

Hiring for:

1st Shift: 6AM - 3PM

3rd Shift: 9PM - 6AM Sun - Thurs

Position Summary: The Utility Operator – Corrugator is a cross-trained, flexible production role that keeps the 98″ Fosber corrugator running without gaps. This person works across the corrugator’s stations — splicer, bridge and preheaters, single facer, double backer, slitter/scorer, and knife/stacker — filling in for breaks and absences, assisting with roll changes and web threading, and catching board quality issues before they reach converting. The role exists to give corrugator supervisors a dependable, trained resource on the machine rather than pulling an operator from a running station or leaving a gap uncovered.

The corrugator is the plant’s production engine. A utility operator who understands how the machine makes board — and what causes it to make bad board — is a meaningful contributor to uptime, waste reduction, and quality. This role is also a developmental pipeline: utility operators who demonstrate mechanical aptitude and consistent performance are natural candidates for full machine operator positions on the corrugator.

About Us

ND Paper is a leading manufacturer of high-quality pulp, paper, and packaging products in the United States, generating over half a billion dollars in annual sales. As a wholly owned subsidiary of Nine Dragons Paper (Holdings) Limited – the largest containerboard producer in the world – ND Paper is part of a global network committed to excellence and innovation. With two integrated pulp and paper mills in Rumford, Maine and Biron, Wisconsin, a packaging plant in Sturtevant, Wisconsin, and two sheeting facilities in Langhorne, Pennsylvania and Fairmont, West Virginia, the ND Paper family produces nearly one million tons of products annually. Our 1,100 dedicated employees are the heart of our operations, and we are committed to fostering positive work environments where individuals can advance and thrive. At ND Paper, we are investing in our future, and that starts with our staff. 

Key Responsibilities & Expected Results:

• Demonstrate safety as a core value and establish a safe work environment by actively leading the safe execution of work. 

• Rotate across corrugator stations as assigned by the supervisor, learning correct operating procedures for each position.
• Understand the corrugator’s process flow — how the single facer, double backer, slitter/scorer, and knife interact — well enough to work at any station without disrupting the run.
• Assist with roll changes, including roll handling with the overhead crane or roll cart, paper webbing, and splice preparation on the splicer.
• Support preheater and wrap adjustments as directed by the machine operator or supervisor.
• Progress through the training matrix toward independent qualification on multiple stations within the 90-day milestone.
• Flag any adjustment outside of trained scope — including starch, heat, or pressure settings — to the operator or supervisor rather than improvising.

• Provide break relief and absence coverage across assigned corrugator stations without disrupting the scheduled run sequence.
• Respond promptly when called to cover an open station; communicate any delay to the supervisor immediately.
• Assist the machine crew during order changes: clearing the bridge, verifying new roll setup, and confirming slitter/scorer settings match the next order.
• Support stacker and takeaway operations — removing finished sheets, stacking, and clearing the runout table — to prevent backups that cause corrugator stops.
• Help manage roll inventory near the corrugator: staging paper rolls in the correct run sequence, reporting low-stock conditions, and moving consumed cores.

• Perform visual quality checks on running board: warp (end-to-end and side-to-side), adhesion, caliper, and print/score placement where applicable.
• Identify suspect board immediately and communicate to the operator or supervisor using the correct reason codes — do not allow defective board to pass to converting.
• Understand the primary causes of common corrugator quality defects — warp, delamination, washboarding, crushed flute — at a working level sufficient to describe what is happening, even if not responsible for the fix.
• Complete required quality and production paperwork accurately, including reason coding for any downtime or waste that occurs during covered stations.

• Follow all lockout/tagout (LOTO), guarding, and PPE requirements without exception. The corrugator presents pinch points, steam, and hot surfaces that require strict adherence.
• Operate the overhead crane or roll handling equipment only if trained and certified; report any equipment or rigging concern to the supervisor before continuing.
• Report near misses, unsafe conditions, and equipment issues immediately — not at the end of the shift.
• Maintain a clean corrugator floor: clear trim scrap, manage paper dust accumulation around the machine, and keep walkways free of waste board and debris.
• Participate in safety training and toolbox talks as scheduled.

• Move paper rolls using roll carts, cranes, or forklifts (if certified) in compliance with load limits and plant traffic rules.
• Stage rolls and medium in the correct sequence for the upcoming production schedule as directed by the supervisor or corrugator operator.
• Return cores to the designated area; assist with downtime material management including roll documentation.
• Coordinate with the warehouse or forklift operator when roll movement requires equipment beyond the utility operator’s current certification.

• Report downtime causes, board quality issues, and material gaps to the supervisor as they occur using correct reason codes.
• Participate in shift handoff communication so incoming crews understand any open machine issues, quality holds, or roll inventory concerns.
• Communicate any equipment anomaly — unusual noise, heat, vibration, or run behavior — to the supervisor or maintenance promptly, even if the machine is still running.

• Knowledge, Skills & Abilities

• Ability to learn multiple positions on a high-speed corrugator and retain procedures across stations.
• Mechanical aptitude and comfort working in a hot, fast-paced environment with large, moving machinery.
• Basic math skills for counting, measuring, and reading order specifications.
• Reliable attendance and willingness to rotate stations and shifts as production requires.
• Ability to read and follow written work instructions in English; bilingual (English/Spanish) communication is a plus given the plant’s workforce.
• Works effectively once trained and asks for direction before improvising on unfamiliar tasks or adjustments.

Key Performance Indicators (KPI’s) 

Performance in this role is evaluated against the following metrics:

• Cross-Training Coverage – Number of corrugator stations (splicer, bridge/preheaters, single facer, double backer, slitter/scorer, knife/stacker) where the utility operator is qualified to work independently. Tracked through the training matrix; targets established after the initial 90-day rotation. 
• Coverage Response – Time required to fill an open station when called for break relief or absence coverage. Baseline collected during the first 60–90 days before setting performance targets. 
• Waste Contribution – Roll and trim waste attributable to stations supported by the utility operator compared to plan. Requires 60–90 days of coded downtime and waste data before establishing meaningful targets. 
• Attendance & Reliability – Scheduled shifts worked compared to shifts missed or late. Standard plant attendance policy applies from day one. 
• Quality Catch Rate – Warp, caliper, or adhesion issues identified and escalated at the corrugator compared to defects that reach converting. Requires consistent use of quality reason codes before establishing a baseline. 
• Safety Compliance – PPE compliance, LOTO adherence, near-miss reporting, and housekeeping audit performance. Tracked from day one; safety expectations apply immediately.

Qualifications and Skills /Education and Experience

Required

• High school diploma or equivalent preferred; equivalent manufacturing or production experience considered.
• Prior experience in corrugated, paper, or heavy manufacturing preferred but not required.
• Overhead crane or forklift certification a plus; certification can be obtained on the job.
• Must be able to pass any pre-employment screening required by plant policy.

punctual — corrugator production depends directly on this role being staffed and active

Preferred

• Ability to learn multiple positions on a high-speed corrugator and retain procedures across stations.
• Mechanical aptitude and comfort working in a hot, fast-paced environment with large, moving machinery.
• Basic math skills for counting, measuring, and reading order specifications.
• Reliable attendance and willingness to rotate stations and shifts as production requires.
• Ability to read and follow written work instructions in English; bilingual (English/Spanish) communication is a plus given the plant’s workforce.
• Works effectively once trained and asks for direction before improvising on unfamiliar tasks or adjustments.
• Bilingual in Mandarin/English a plus

Physical Requirements

• Stands, walks, lifts, and bends throughout a full shift on a concrete production floor near a continuously running machine.
• Lifts and carries up to 50 lbs. regularly; assists with staged rolls using mechanical aids.
• Works in a hot environment — the corrugator runs steam and heated rolls — with exposure to noise, paper dust, and varying temperatures throughout the shift; required PPE (hearing protection, safety glasses, steel-toe footwear, heat-resistant gloves where applicable) must be worn at all times on the corrugator floor.
• Must be able to work assigned shift, including overtime and weekend coverage as production demands require.

Core Competencies (Results based)

• Cross-Training & Operational Flexibility – Demonstrates the ability to learn and independently operate multiple corrugator stations to support production needs. 
• Equipment Operation & Process Awareness – Understands corrugator processes, equipment functions, and operating standards to maintain safe and efficient production. 
• Quality Focus & Problem Identification – Recognizes process variations, identifies quality concerns, and escalates issues before defects reach converting. 
• Teamwork & Responsiveness – Provides timely support for staffing needs, break relief, and production coverage while working effectively with the corrugator team. 
• Safety & Work Discipline – Follows PPE, LOTO, housekeeping, and safety procedures while actively contributing to a safe work environment. 
• Reliability & Accountability – Maintains strong attendance, follows standard work, and takes ownership of assigned responsibilities.

Success Profile (What great looks like)

30 Days