Extrusion Process Engineer

The role ensures production readiness through the development and maintenance of process documentation, tooling requirements, equipment specifications, quality controls, and manufacturing standards.

The successful candidate will work closely with Operations, Quality, Supply Chain, Product Development, and Maintenance teams to drive process capability, productivity, quality, and cost improvements while maintaining high standards of Health, Safety, Environmental and Quality (HSEQ) performance. 

ESSENTIAL

• Develop, implement, optimize, and sustain extrusion manufacturing processes.

• Lead process validation activities including trials, capability studies, first-off approvals, and process qualification.

• Define and maintain process parameters, control plans, setup standards, and manufacturing specifications.

• Support New Product Introduction (NPI) activities and ensure successful transfer from development into production.

• Develop and maintain Standard Operating Procedures (SOPs), Work Instructions, Risk Assessments, and Process FMEAs.

• Monitor and improve key process metrics including yield, scrap, throughput, OEE, cycle times, energy consumption, and quality performance.

• Investigate process deviations, non-conformances, and customer complaints using structured problem-solving methodologies.

• Identify and implement continuous improvement projects to enhance safety, quality, delivery, productivity, and cost performance.

• Drive root cause analysis and corrective actions using Lean Manufacturing and Six Sigma methodologies.

• Collaborate with Production, Quality, Maintenance, and Engineering teams to resolve technical issues and improve process reliability.

• Lead process capability assessments and establish control measures for critical-to-quality (CTQ) characteristics.

• Develop manufacturing cost models and support capacity planning activities.

• Analyse production data and generate reports to support business decision-making.

• Provide day-to-day technical support to extrusion operations and manufacturing personnel.

• Support training and competency development of operators, technicians, and engineers.

• Participate in HSE initiatives including observations, risk reduction activities, and continuous improvement programs.

• Perform other duties as required by the business.

  Safety

• Ensure that the Safety policies and procedures are understood and adhered to, so far as is reasonably practicable, in order to ensure a safe working environment.

  Other

• Carry out work in accordance with the Company Health, Safety, Environmental and Quality Systems.

• Perform the assigned tasks with due diligence regarding the Integrated Management Systems on the Company.

• Eliminate waste of whatever form, to suggest the use of more environmentally friendly substances and practices and contribute to the continuous improvement of the environment.

REQUIRED

• Minimum HNC in a technical discipline.

• Demonstrable experience in extrusion manufacturing or a related continuous process manufacturing environment.

• Experience developing and optimizing manufacturing processes.

• Strong understanding of process capability, statistical analysis, and manufacturing quality systems.

• Experience with root cause analysis and continuous improvement techniques.

• Proficient in Microsoft Office applications and manufacturing data analysis tools.

DESIRED

• Bachelor's degree in manufacturing engineering, Mechanical Engineering, Materials Engineering, Polymer Engineering, Chemical Engineering, or equivalent technical discipline.

• Experience with polymer, thermoplastic, elastomer, cable, tubing, or composite extrusion processes.

• Knowledge of extrusion dies, tooling design, material flow, temperature control, cooling systems, and downstream equipment.

• Lean Manufacturing and/or Six Sigma certification.

• Experience with SPC, PFMEA, Control Plans, and APQP methodologies.

• Awareness of automation, PLC controls, and process monitoring systems.