Plastic Extrusion Engineer

REPORTS TO:

Plant Manager / Vinyl Department Manager

SUPERVISION EXERCISED:                            

Extrusion Technicians, Process Technicians, Production Support Personnel, Operators, and Vinyl Personnel

GENERAL STATEMENT OF DUTIES:

Responsible for developing, improving, and supporting plastic extrusion manufacturing processes to ensure safety, quality, efficiency, and production goals are achieved. Will provide technical expertise in Saluka processing, rigid and flexible extrusion applications, and single and dual durometer extrusion systems. Will troubleshoot extrusion issues, optimize tooling and machine performance, support product development activities, and lead continuous improvement initiatives throughout the extrusion department.

EXAMPLES OF DUTIES:

(This list may not include all duties assigned)

1. Develop, implement, and optimize extrusion processes to improve product quality, efficiency, and throughput.
2. Provide technical support for all extrusion operations, including rigid, flexible, single durometer, and dual durometer products.
3. Maintain extensive knowledge of Saluka processing methods and material characteristics.
4. Troubleshoot extrusion processing issues related to dimensional stability, appearance, melt flow, adhesion, chatter, warpage, and surface defects.
5. Analyze and improve extrusion line performance, including screw design, tooling, downstream equipment, cooling systems, and material handling systems.
6. Assist in startup, setup, and validation of new extrusion lines, tooling, and product launches.
7. Conduct process capability studies and establish process parameters and operating standards.
8. Develop and maintain standard operating procedures for extrusion processes and equipment.
9. Work closely with Quality Control to ensure all products meet customer specifications and quality standards.
10. Analyze production data and implement corrective actions to reduce scrap, downtime, and inefficiencies.
11. Support material trials involving rigid PVC, flexible PVC, co-extrusion materials, additives, color concentrates, and specialty compounds.
12. Collaborate with maintenance personnel to improve equipment reliability and preventative maintenance practices.
13. Assist with tooling design reviews and recommend process improvements for new and existing products.
14. Understand and optimize processing conditions, including temperature profiles, screw speeds, vacuum systems, cooling rates, and haul-off settings.
15. Lead continuous improvement initiatives utilizing lean manufacturing and process optimization techniques.
16. Train extrusion personnel on proper processing techniques, troubleshooting methods, and operational best practices.
17. Monitor and improve material usage, BOM accuracy, and production yields.
18. Participate in R&D activities for new materials, compounds, tooling, and extrusion technologies.
19. Evaluate and recommend new extrusion technologies and process improvements to increase operational efficiency.
20. Ensure compliance with all company safety policies, quality standards, and environmental regulations.
21. Maintain accurate process documentation, trial reports, and engineering records.
22. Support cross-functional teams, including production, quality, maintenance, engineering, and supply chain.
23. Assist in developing corrective and preventive actions related to extrusion quality concerns.
24. Maintain a clean, safe, and organized work environment.
25. Perform additional duties as assigned by management.

Knowledge, Skills, & Abilities:

Comprehensive knowledge of plastic extrusion processes, including Saluka processing, rigid and flexible extrusion, single and dual durometer applications, co-extrusion systems, tooling design, and material flow characteristics. Strong troubleshooting and analytical skills required. Ability to interpret blueprints, technical drawings, process documentation, and engineering specifications. Strong communication, organizational, leadership, and project management skills required. Proficiency with Microsoft Office and manufacturing systems is preferred.

Knowledge of:

• Extrusion screw and die design.
• PVC processing and compounding
• Rigid and flexible material characteristics
• Process optimization and continuous improvement.
• Statistical process control and quality systems
• Lean manufacturing principles
• Troubleshooting extrusion defects and process variation

Education:

Bachelor’s degree in Engineering, Plastics Engineering, Manufacturing Engineering, or related technical field preferred.

Equivalent extrusion processing experience may be considered.

Experience:

• Minimum of 5 years of plastic extrusion manufacturing experience preferred.
• Experience with Saluka processing is strongly preferred.
• Experience with rigid and flexible PVC extrusion required.
• Experience with single and dual-durometer extrusion processes preferred.
• Previous process engineering or manufacturing engineering experience preferred.
• Experience leading continuous improvement initiatives preferred.
• Injection Molding experience is plus