Extrusion Supervisor

About the role

The Extrusion Supervisor is responsible for overseeing daily extrusion operations, ensuring consistent product quality, meeting production targets, optimizing line efficiency, and maintaining a safe working environment. This role demands strong technical knowledge of plastic extrusion processes combined with proven leadership skills.

Responsibilities

• Directly supervise, train, and mentor a team of extrusion operators, technicians, and material handlers (typically 6–12 direct reports).
• Oversee daily production schedules across multiple extrusion lines to ensure on-time delivery of high-quality products.
• Monitor and optimize extrusion processes, including melt temperature, screw speed, haul-off speed, cooling, and dimensional control.
• Troubleshoot common extrusion issues such as dimensional variations, surface defects, melt fracture, surging, and die swell.
• Manage setup, changeovers, and startup/shutdown procedures for extruders and downstream equipment.
• Work closely with Quality, Engineering, and Maintenance teams to resolve process and quality concerns.
• Enforce all safety policies and procedures (OSHA compliance, lockout/tagout, PPE, machine guarding) and lead safety meetings.
• Track and report key performance indicators (KPIs): line efficiency, scrap rate, uptime, throughput, and OEE.
• Control raw material usage (resins, additives, colorants) and minimize waste.
• Lead continuous improvement initiatives using Lean Manufacturing, 5S, and Kaizen methodologies.
• Conduct employee performance reviews, coaching, disciplinary actions, and participate in hiring decisions.
• Ensure compliance with company policies, ISO/QMS standards, and all regulatory requirements.

Requirements

• Minimum 5+ years of hands-on experience in plastic extrusion, with at least 2–3 years in a supervisory or lead role.
• Strong technical knowledge of single-screw and twin-screw extruders, dies, calibrators, haul-offs, cutters, winders, and auxiliary equipment.
• Experience with a variety of polymers including HDPE, LDPE, PP, PVC, ABS, PC, and engineering resins.
• Proven ability to troubleshoot extrusion defects and optimize process parameters for consistent quality and output.
• Familiarity with Lean Manufacturing principles and continuous improvement tools.
• Strong leadership, communication, and team-building skills.
• Proficient in Microsoft Office (Word, Excel, Outlook) and ERP/MRP systems.
• Ability to read and interpret technical drawings, blueprints, and process specifications.
• Formal training in extrusion technology (e.g., Paulson, Rauwendaal, or equivalent).
• Experience with profile extrusion, pipe/tubing, sheet, film, or compounding.
• Knowledge of die design, maintenance, and repair.
• Experience with statistical process control (SPC) and quality systems.
• Bilingual (English/Spanish) is a plus.

Physical Requirements

• Ability to stand for long periods, walk production floor, and climb stairs/ladders as needed.
• Capable of lifting up to 50 lbs occasionally.
• Comfortable working in a manufacturing environment with noise, heat, and moving machinery.
• Willingness to work flexible shifts, including overtime, nights, and weekends when required.