What are the responsibilities and job description for the Extrusion Operator position at Shakespeare Company LLC?
JOB DESCRIPTION
Position Summary
The Extrusion Operator safely operates and monitors extrusion lines to produce monofilament products that meet customer specifications for quality, output, and consistency. This role is responsible for machine setup, process monitoring, basic troubleshooting, and ensuring adherence to production and quality standards. Newly hired team members will receive New Hire Orientation, Shakespeare Safety Orientation, SPC training and utilization of statistical software (NWA), and Forklift/Pallet Jack training and certification.
Essential Functions
- Read and comprehend shop order, Bill of Materials (BOM), process & product specifications, and special instructions.
- Pack filled spools, label spools/cartons/boxes according to instructions.
- Identify and locate parts according to BOM.
- Neatly and accurately fill out all extrusion paperwork.
- Set up, start up, and stop extruder according to process/procedures.
- Perform testing, tie up product, keep hopper filled, separate lines in quench tank and doff lines.
- Set up and operate doff timers/metered yardage systems/doff to buzzer to control yardage, maintain wind quality.
- Check and set winding tensions, operate, and monitor computers, laser mics, reports, enter data into NWA, identify out of control conditions.
- Monitor equipment/process setup against specifications, understand corrective actions.
- Efficiently manage/complete changeovers from one product to another.
- Troubleshooting (Basic) - startup / target properties with assistance
- Understand different types of die packs & their installation/removal procedure
- Put roll stands in correct gear ratio per product; know when it's required
- Set additive equipment to process, monitor and keep filled
- Cook out, flush out, and purge extruder & understand when each type of clean out is required
- Recognize quality problems based on QA data SPC/visual inspections, process equipment inspections
- Use additives and understand the purpose of these additives
- Troubleshoot equipment, additives, diameter measurement to root cause
-
Execute the “changeover” from one product to another product:
- Remove and load drying system
- Change winder components
- Execute die change
- Execute finish change
- Input process settings (i.e., extruder, roll stands and winders)
- Complete startup and sample testing requirement
Secondary Functions
- Work in a safe manner and maintain general housekeeping
- Demonstrate commitment to customer quality, business results and continuous improvement
- Expected to increase knowledge and progressively improve individual performance
- Manage daily tasks to achieve target production rates
- Other assignments as requested
Position Specifications
- Shift work required
- Overtime required as needed to cover absences/vacations
- Strong listening and communication skills
- Strong attention to detail and organization skills required
- Strong mechanical aptitude and ability to troubleshoot problems
- Basic computer skills
- Must demonstrate commitment to safety
- Must demonstrate a willingness and desire to learn
- Must demonstrate effective time management and sound judgment
- Ability to make basic mathematical calculations (including addition, subtraction, finding averages)
- Ability to read information and numbers and write legibly
- Must demonstrate a willingness to assist other operators when necessary
Qualifications
Required:
- High school diploma or equivalent
- Basic math and reading skills
- Ability to follow written and verbal instructions
Preferred:
- Experience in extrusion or manufacturing operations
- Mechanical aptitude and troubleshooting ability
Physical Requirements / Work Environment:
- Manufacturing environment with exposure to heat, noise, and dust
- Ability to stand for extended periods (6–8 hours) / 12-hour shifts.
- Ability to lift up to 50 lbs.
- Frequent bending, climbing, and manual dexterity are required.
- Ability to use motorized equipment (forklift, pallet jack).
- Hand /finger agility: grasp, move, adjust, tie knots, utilize scissors.
- Able to wear PPE: steel-toed footwear, hearing protection, safety glasses.
General Skills and Competencies:
- Attention to detail and quality focus
- Mechanical aptitude
- Basic computer/data entry skills
- Teamwork and communication
- Strong work ethic and reliability
Skills Progression Matrix
There are 8 pay rates within the Extrusion operator position, based on the employee’s knowledge, skill, and experience.
Operators may advance to the next pay rate once they have met the skill level description and pre-requisites. (see next page)
Skill Level
Skill Level Description Summary
Pre-requisites to advance
Comments
Trainee
Able to learn and follow instructions
Adhere to company attendance and safety policies
Read and comprehend shop order, BOM process & specifications
Pack filled spools, label spools/carton/boxes according to instructions
Identify and locate parts according to BOM
Neatly and accurately fill out all extrusion paperwork
Set up, start up and stop extruder according to process/procedures
Perform testing, tie lines, keep hopper filled, separate lines in quench tank
Able to doff trimmer line without assistance
Demonstrate good housekeeping practices
Must complete Orientation Training. Must complete successful interview with dept manager, team lead, trainer.
Trainees generally progress to level 1 in less than 6 months by successfully demonstrating all 23 skills tasks for Extrusion trainee, and all 17 skills tasks for level 1
Level 1
Ability to work independently
Able to operate 1 machine and doff .015
mil and above w/ assistance
Set up operate doff timers/metered yardage systems/doff to buzzer to control yardage, wind quality
Identify different types of resins on BOM
Use proper procedure for handling empty drums, label, report and dispose of scrap
Check and set winding tensions, operate and monitor computers, laser mics, print reports, enter data into NWA, identify out of control conditions
Check line for diameter, slubs, flicks
Label, isolate, rejected material
Change resin and finish following procedures
Monitor equipment/process setup against specifications, understand corrective actions
Must have no active disciplinary actions
Must have successfully demonstrated all 23 skills tasks for Extrusion trainees, and all 17 skills for level 1
Operators generally advance from level 1 to level 2 in less than 18 months.
Level 2
Operate 1 machine efficiently with minimal assistance
Efficiently manage / complete changeovers
Troubleshooting (Basic) - startup / target properties with assistance
Follow die change and cleaning intervals
Understand different types of die packs & their installation/removal procedures
String up and separate lines with assistance from another operator 7 mil and above
Doff .012 mil and above without assistance
Set up winder and traverse
Cook out
Put roll stands in correct gear ratio per product; know when it's required
Cook out, flush out, purge extruder & understand when each type of clean out is required
Set additive equipment to process, monitor and keep filled
Must have no active disciplinary actions.
Must have successfully demonstrated a minimum 10 of 11 skill tasks for level 2 operator.
Operators generally advance from level 2 to level 3 in less than 18 months.
Level 3
Able to doff and string in .008 mil and above without assistance
Trouble shooting (advanced) Procedures ID problems/troubleshoot quality/process issues
Experience with additives and understanding the purpose of these additives
Cook out, flush, AJAX extruder & understand when each type of clean out is required
Recognize quality problems based on QA data SPC/visual inspections, process equipment inspections
Operate 2 machines with assistance
Must have no active disciplinary actions.
Must have successfully demonstrated a minimum 5 of 6 skill task for level 3 operator.
Operators generally advance from level 3 to level 4 in less than 24 months.
Level 4
Able to run any machine
Must be able to doff and operate all winders and understand winder operation
Able to doff .005 mil and above
Trouble shoot without assistance equipment, additives, diameter measurement to root cause
Run his/her machines and assist other operators and promote teamwork
Be willing to train new associates
Able to operate 2 machines efficiently
Must have no active disciplinary actions.
Must have successfully demonstrated a minimum 6 of 7 skill task for level 4 operator.
Operators are expected to assist team leads / be willing to train / backfill team lead position
Operators can run 1 of 5 specialty products / Machines
- BSN/Ribbon (Ex1001)
- Dental Floss (NX-1042)
- Lab line
- Bico products (BC-108)
- Mach 36 (R&D)
Level 5
Able to run any machine and any product
Must be able to doff and operate all winders and understand winder operation
Able to doff any size filaments
Trouble shoot without assistance equipment, additives, diameter measurement to root cause
Run his/her machines and assist other operators and promote teamwork
Able to run EX1001 & HPA Products
Be willing to train new associates
Must have no active disciplinary actions.
Must have successfully demonstrated a minimum 6 of 7 skill task for level 4 operator.
Operators are expected to assist team leads / be willing to train / backfill team lead position
Operators can run 2 of 5 specialty products / Machines
- BSN/Ribbon (Ex1001)
- Dental Floss (NX-1042)
- Lab line
- Bico products (BC-108)
- Mach 36 (R&D)
Level 6
Able to run any machine and any product
Must be able to doff and operate all winders and understand winder operation
Able to doff any size filaments
Trouble shoot without assistance equipment, additives, diameter measurement to root cause
Run his/her machines and assist other operators and promote teamwork
Able to run EX1001 & HPA Products
Be willing to train new associates
Must have no active disciplinary actions.
Must have successfully demonstrated a minimum 6 of 7 skill task for level 4 operator.
Operators are expected to assist team leads / be willing to train / backfill team lead position
Operators can run 3 of 5 specialty products / Machines
- BSN/Ribbon (Ex1001)
- Dental Floss (NX-1042)
- Lab line
- Bico products (BC-108)
- Mach 36 (R&D)
Level 7
Able to run any machine and any product
Must be able to doff and operate all winders and understand winder operation
Able to doff any size filaments
Trouble shoot without assistance equipment, additives, diameter measurement to root cause
Run his/her machines and assist other operators and promote teamwork
Able to run EX1001 & HPA Products
Be willing to train new associates
Must have no active disciplinary actions.
Must have successfully demonstrated a minimum 6 of 7 skill task for level 4 operator.
Operators are expected to assist team leads / be willing to train / backfill team lead position
Operators can run 4 of 5 specialty products / Machines
- BSN/Ribbon (Ex1001)
- Dental Floss (NX-1042)
- Lab line
- Bico products (BC-108)
- Mach 36 (R&D)
Level 8
Able to run any machine and any product
Must be able to doff and operate all winders and understand winder operation
Able to doff any size filaments
Trouble shoot without assistance equipment, additives, diameter measurement to root cause
Run his/her machines and assist other operators and promote teamwork
Able to run EX1001 and HPA Products
Be willing to train new associates
Must have no active disciplinary actions.
Must have successfully demonstrated a minimum 6 of 7 skill task for level 4 operator.
Operators are expected to assist team leads / be willing to train / backfill team lead position
Operators can run 5 of 5 specialty products / Machines
- BSN/Ribbon (Ex1001)
- Dental Floss (NX-1042)
- Lab line
- Bico products (BC-108)
- Mach 36 (R&D)
The above statements describe the general nature and level of responsibilities for these positions and are not to be construed as an exhaustive list of all responsibilities, duties, and skills required of this position. Company management may assign other relevant, business-related duties.