Job Description

We are seeking an experienced Senior Plastic Extrusion Process Engineer to join our dynamic manufacturing team. The ideal candidate will have 8-10 years of hands-on experience in plastic extrusion processes, a deep understanding of polymer materials, and a proven track record of optimizing production efficiency, quality, and safety. This role will involve leading process improvements, troubleshooting complex issues, and mentoring junior engineers while collaborating with cross-functional teams to drive innovation and operational excellence. Key Responsibilities:

• Design, develop, and optimize plastic extrusion processes, including single-screw and twin-screw extrusion, to meet production goals and quality standards.
• Lead the selection, testing, and validation of polymer materials and additives for specific extrusion applications.
• Analyze and troubleshoot process issues, identifying root causes and implementing corrective actions to minimize downtime and scrap rates.
• Develop and maintain process documentation, including standard operating procedures (SOPs), work instructions, and process flow diagrams.
• Collaborate with R&D, quality assurance, and production teams to support new product development and scale-up from prototype to full production.
• Oversee equipment setup, calibration, and maintenance to ensure consistent performance and compliance with safety regulations.
• Drive continuous improvement initiatives using Lean, Six Sigma, or similar methodologies to enhance efficiency, reduce waste, and lower costs.
• Train and mentor junior engineers and technicians on extrusion techniques, equipment operation, and best practices.
• Ensure compliance with industry standards, environmental regulations, and workplace safety protocols (e.g., OSHA, ISO).
• Monitor key performance indicators (KPIs) such as cycle time, yield, and defect rates, providing regular reports to management.

Qualifications:

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, or a related field (Master’s degree preferred).
• 8-10 years of direct experience in plastic extrusion process engineering within a manufacturing environment.
• Expertise in polymer processing, including knowledge of thermoplastics (e.g., PVC, PE, PP, ABS) and their behavior during extrusion.
• Proficiency with extrusion equipment, tooling design, and downstream processes (e.g., cooling, cutting, co-extrusion).
• Strong analytical skills with experience in statistical process control (SPC), Design of Experiments (DOE), and root cause analysis.
• Familiarity with CAD software (e.g., AutoCAD, SolidWorks) for designing extrusion dies or tooling is a plus.
• Demonstrated leadership skills with experience mentoring teams or leading projects.
• Excellent communication skills, both written and verbal, with the ability to collaborate across departments.
• Certification in Lean Six Sigma (Green Belt or higher) is highly desirable.
• Knowledge of regulatory standards such as ISO 9001, ISO 14001, or FDA requirements (if applicable).

Preferred Skills:

• Experience with advanced extrusion technologies, such as multi-layer extrusion or profile extrusion.
• Hands-on experience with automation systems and Industry 4.0 principles in manufacturing.
• Ability to manage multiple projects in a fast-paced environment while meeting deadlines.

Benefits:

• Competitive salary commensurate with experience.
• Health, dental, and vision insurance.
• 401(k) with company match.
• Paid time off and holidays.
• Opportunities for professional development and career advancement.