Plant SupervisorTwin Screw Thermoplastic Compounding

TPE Solutions, Inc.; Ayer (MA); On-site; USD 100,000 - 140,000; Full time

Benefits offered by this job

401(k)

401(k) matching

Competitive salary

Dental insurance

Health insurance

Paid time off

Job summary

TPE Solutions, Inc. is seeking an experienced Plant Manager for our facility in Ayer, Massachusetts. This role requires a hands-on leader to oversee all manufacturing operations, ensuring efficient and safe production while maintaining high quality standards.

The ideal candidate will have extensive experience with twin screw extrusion and a proven track record in manufacturing leadership. Join us to develop world-class operations in highly engineered thermoplastic compounding.

Qualifications

• Minimum 10 years of hands-on twin screw thermoplastic compounding experience.
• Minimum 5 years of manufacturing leadership or plant management experience.
• Strong knowledge of thermoplastics and polymer additives.

Responsibilities

• Direct daily manufacturing operations to meet production & quality objectives.
• Provide technical leadership and optimize twin screw extrusion operations.
• Ensure compliance with safety regulations and company policies.

Skills

Hands-on twin screw thermoplastic compounding experience

Manufacturing leadership skills

Problem-solving skills

Understanding of Lean Manufacturing principles

Education

Bachelor's degree in Engineering or related field

Tools

Microsoft Office

ERP/MRP systems

Job description

Benefits:

• 401(k)
• 401(k) matching
• Competitive salary
• Dental insurance
• Free uniforms
• Health insurance
• Opportunity for advancement
• Paid time off
• Profit sharing
• Training & development

Position Summary

XPM Plastics Compounding is seeking an experienced, hands‑on Plant Manager to lead all manufacturing operations within our custom thermoplastic compounding facility. This position is responsible for the safe, efficient, and profitable operation of the plant while maintaining the highest standards of quality, customer service, and continuous improvement.

This is not a desk‑only management position. The successful candidate will possess extensive hands‑on experience with twin screw extrusion and will be expected to actively support production, troubleshoot processing issues, optimize manufacturing processes, and mentor production personnel.

Essential Responsibilities

Plant Operations

• Direct all daily manufacturing operations, including production, maintenance, quality, warehouse, shipping, receiving, and scheduling.
• Ensure production schedules are achieved while meeting quality, cost, and delivery objectives.
• Maximize equipment utilization and overall plant efficiency.
• Monitor production metrics, downtime, scrap, labor efficiency, and throughput.
• Develop and implement continuous improvement initiatives throughout the facility.

Twin Screw Extrusion Leadership

• Provide technical leadership for twin screw extrusion operations.
• Optimize extrusion processes for productivity, quality, and cost.
• Troubleshoot processing issues involving polymers, additives, fillers, color concentrates, feeding systems, pelletizing, and downstream equipment.
• Develop and maintain process documentation, machine setup parameters, and standard operating procedures.
• Lead scale‑up of new formulations from development through commercial production.
• Work closely with engineering and customers to develop manufacturable processing solutions.

Quality & Continuous Improvement

• Ensure products consistently meet customer specifications and quality standards.
• Support ISO 9001 and other applicable quality systems.
• Lead root cause investigations and implement corrective and preventive actions.
• Drive waste reduction, process optimization, and productivity improvements.

Safety & Compliance

• Foster a strong culture of workplace safety.
• Ensure compliance with OSHA regulations and all environmental requirements.
• Lead safety meetings, incident investigations, and corrective actions.
• Maintain clean, organized, and efficient manufacturing operations.

Leadership

• Recruit, train, mentor, and develop production personnel.
• Establish clear performance expectations and accountability.
• Promote teamwork, communication, and employee engagement.
• Work collaboratively with Sales, Engineering, Quality, Purchasing, Customer Service, and Executive Leadership.

Financial & Operational Performance

• Manage plant operating budgets and labor utilization.
• Control manufacturing costs while maintaining product quality.
• Support capital equipment planning and implementation.
• Develop KPIs and report plant performance to executive management.

Required Qualifications

• Minimum 10 years of hands‑on twin screw thermoplastic compounding experience (required).
• Minimum 5 years of manufacturing leadership or plant management experience.
• Demonstrated experience operating and troubleshooting co‑rotating twin screw extruders.
• Strong knowledge of thermoplastics, polymer additives, fillers, reinforcements, color concentrates, and engineered compounds.
• Experience with gravimetric feeding systems, pelletizing systems, dryers, blenders, material handling, and downstream processing.
• Ability to optimize screw designs, process conditions, and production efficiencies.
• Strong understanding of manufacturing metrics and Lean Manufacturing principles.
• Experience implementing continuous improvement initiatives.
• Excellent leadership, communication, and problem‑solving skills.
• Proficient with Microsoft Office and ERP/MRP systems.

Preferred Qualifications

• Bachelor's degree in Engineering, Polymer Science, Manufacturing, or a related field.
• Experience with highly engineered thermoplastic compounds.
• Knowledge of medical, automotive, consumer, industrial, or specialty polymer markets.
• Experience with color matching and formulation development.
• Working knowledge of laboratory testing and material characterization.

Success in This Role

The successful Plant Manager will:

• Lead by example and work alongside the production team when needed.
• Solve complex processing challenges quickly and effectively.
• Build a culture centered on safety, accountability, and continuous improvement.
• Deliver consistent product quality while maximizing plant productivity.
• Develop employees into highly skilled manufacturing professionals.
• Help position XPM Plastics Compounding as a premier custom twin screw compounding company.

Why Join XPM Plastics Compounding?

At XPM Plastics Compounding, we specialize in highly engineered thermoplastic compounds and challenging processing applications. We invest in advanced compounding technology, technical expertise, and exceptional customer service to solve problems others cannot. Our team values innovation, integrity, and hands‑on manufacturing excellence.

If you have extensive twin screw extrusion experience and are passionate about building world‑class manufacturing operations, we encourage you to apply.