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Extrusion Operator

Shakespeare Company LLC -
Columbia, SC

Job Details

Full-time

Qualifications

Safety protocol adherence
Personal protective equipment (PPE) use
Scissors
Machine operation
Shop math
High school diploma or GED
Safety equipment
Pallet jack
Material handling equipment operation

Full Job Description

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.

Essential Functions

Secondary Functions

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