Lead Extruder Operator

Job Description

Job Description:\n\nLead Extruder Operator – Extrusion\nLocation: 2577 AR-59, Decatur, ARDepartment: ProductionJob Type: Full-Time, On-SiteReports To: Production Shift SupervisorClassification: Hourly, Non-ExemptSchedule: Assigned production shift, with overtime and weekend work as operationally required\nAbout United Petfood\nUnited Petfood is a private label producer of high-quality dry & wet pet food, biscuits and snacks. We are a Belgian family business with 25 high-tech pet kitchens in Europe and the US.\nJoining us means joining an international, passionate, and driven team with one common goal: a healthy planet filled with healthy pets! But it doesn’t stop there—we truly care about building encouraging, supportive, long-lasting partnerships, both inside as well as outside of our fast-growing family company. By only working with the very best ingredients and most innovative technology available, we ensure a place in which you can grow, bloom, and make thousands of pets happy worldwide!\nCheck out our website: United Petfood Producers USA, Inc.\nPosition Summary\nThe Lead Production Operator – Extrusion is a working lead responsible for coordinating daily extrusion operations, providing direction and technical guidance to production employees, and ensuring safe, efficient, and consistent production of high-quality dry pet food at United Petfood's Decatur, Arkansas facility.\nThis position combines advanced extrusion equipment operation and troubleshooting with day-to-day team coordination, employee training, production scheduling support, and monitoring of production performance.\nThe Lead Production Operator works closely with the Production Shift Supervisor to coordinate employee assignments, communicate production priorities, monitor equipment and product performance, and address operational issues. The position serves as a primary point of contact for operators during the shift and helps ensure production activities meet established safety, quality, food safety, and efficiency requirements.\nAs a working lead, the employee is expected to perform hands-on extrusion duties while providing guidance, training, and operational direction to other operators. Formal personnel management and disciplinary decisions remain the responsibility of designated management.\nDuties & Responsibilities\nProduction Leadership & Team Coordination\n\n Coordinate daily extrusion operations and support the execution of assigned production schedules.\n Provide day-to-day work direction, technical guidance, and operational support to production operators.\n Assist the Production Shift Supervisor with assigning and prioritizing employee tasks based on production requirements, staffing, equipment availability, and operational needs.\n Monitor production progress and communicate priorities to ensure scheduled production targets are met.\n Lead or assist with shift startup meetings and production huddles to communicate safety expectations, production goals, quality concerns, and operational updates.\n Serve as a liaison between production operators, the Production Shift Supervisor, Maintenance, and Food Safety & Quality Assurance (FSQA).\n Monitor employee adherence to established operating procedures, GMPs, and safety requirements.\n Identify and address routine operational concerns within assigned authority and escalate unresolved issues to the Production Shift Supervisor.\n Assist with coordinating employee coverage and work assignments during breaks, changeovers, and production interruptions.\n Communicate equipment status, production progress, staffing concerns, and outstanding issues during shift pass-downs.\n Support an organized, efficient, and productive work environment.\n Promote teamwork, accountability, and continuous improvement throughout the assigned production area.\n\nExtrusion Equipment Operation & Setup\n\n Independently set up, start, operate, monitor, and shut down extrusion equipment in accordance with Standard Operating Procedures (SOPs), Good Manufacturing Practices (GMPs), and production schedules.\n Operate and support extrusion processing equipment and associated production systems used in dry pet food manufacturing.\n Perform complex equipment setups, adjustments, calibrations, and product changeovers.\n Perform authorized die changes and related equipment adjustments to meet required kibble sizes, shapes, and product specifications.\n Review production schedules, formulations, processing instructions, and equipment requirements before initiating production.\n Verify equipment readiness and availability of required materials before production startup.\n Monitor extrusion equipment performance and make authorized adjustments to maintain stable operating conditions.\n Coordinate equipment startup, shutdown, cleaning, and changeover activities to minimize production interruptions.\n Properly disassemble, clean, inspect, and reassemble extrusion equipment in accordance with established procedures.\n Assist operators with complex equipment setups, changeovers, and operating challenges.\n\nProcess Monitoring & Product Quality\n\n Monitor extrusion process performance to ensure products consistently meet established specifications.\n Verify product appearance, size, shape, and other required characteristics using visual inspections and approved measuring devices, including micrometers where applicable.\n Monitor and document required processing parameters, including temperature, moisture, and other applicable operating conditions.\n Perform or coordinate required in-process product checks and sampling in accordance with established procedures.\n Monitor product quality during startups, changeovers, and routine production.\n Identify processing deviations and make authorized adjustments to maintain product consistency and quality.\n Verify that required production and quality checks are completed accurately and at established frequencies.\n Communicate product quality concerns, process deviations, or potentially nonconforming materials to Production leadership and FSQA.\n Follow established procedures for product holds, rework, and disposition of nonconforming materials.\n Ensure product identification, traceability, and production documentation requirements are maintained.\n\nEquipment Troubleshooting & Maintenance Support\n\n Provide advanced troubleshooting support for extrusion equipment and associated production systems.\n Identify and resolve routine and complex operating issues within established procedures and authorized responsibilities.\n Perform authorized minor adjustments, equipment care, and basic maintenance activities.\n Inspect equipment for abnormal operating conditions, wear, damage, or potential failures.\n Coordinate with Maintenance personnel regarding equipment breakdowns, repairs, and preventive maintenance needs.\n Assist with equipment testing and verification following maintenance activities.\n Communicate recurring equipment problems and recommend corrective actions.\n Support equipment reliability initiatives and improvements intended to reduce unplanned downtime.\n\nEmployee Training & Development\n\n Assist with onboarding and training new production employees in assigned work areas.\n Provide hands-on instruction regarding equipment operation, production procedures, safety requirements, GMPs, and quality standards.\n Demonstrate proper equipment setup, operation, changeovers, troubleshooting, and documentation practices.\n Reinforce established work instructions and standard operating procedures.\n Monitor employee understanding of assigned tasks and provide constructive coaching and technical guidance.\n Identify additional training needs and communicate observations to the Production Shift Supervisor.\n Assist with cross-training employees to support operational flexibility and coverage.\n Support employee development and continuous improvement of technical operating skills.\n Help maintain a positive, respectful, and collaborative team environment.\n\nProduction Performance & Continuous Improvement\n\n Monitor production performance, equipment efficiency, and progress toward scheduled production targets.\n Identify operational delays, equipment limitations, process concerns, and opportunities for improvement.\n Coordinate with Production leadership to minimize downtime, reduce waste, and improve product consistency.\n Support effective equipment changeovers and production transitions.\n Participate in troubleshooting discussions, root cause analysis, and continuous improvement initiatives.\n Recommend improvements to operating practices, equipment reliability, production flow, and employee training.\n Assist with implementation of approved process improvements.\n Promote efficient use of materials, equipment, labor, and production resources.\n\nProduction Documentation & Communication\n\n Complete and review production records, equipment logs, process monitoring documentation, and other required records.\n Verify that production operators complete required documentation accurately and on time.\n Record production activity, equipment settings, downtime, product deviations, and other required information in designated systems.\n Communicate production status, equipment issues, quality concerns, and operational priorities to the Production Shift Supervisor.\n Maintain accurate information during product changeovers, equipment adjustments, and production interruptions.\n Support accurate shift pass-down communication and documentation.\n Report documentation discrepancies and coordinate corrections in accordance with established procedures.\n Perform other related duties as assigned.\n\nRequired Qualifications\n\n High school diploma or equivalent.\n Minimum of three years of experience operating extrusion equipment in a manufacturing environment.\n Minimum of one year of experience in a manufacturing lead role or equivalent demonstrated experience coordinating production activities and providing technical guidance to employees.\n Advanced knowledge of extrusion equipment setup, operation, troubleshooting, and process adjustments.\n Demonstrated ability to independently operate and troubleshoot manufacturing equipment.\n Strong mechanical aptitude and ability to use hand tools and measuring devices.\n Ability to interpret production schedules, SOPs, equipment instructions, and product specifications.\n Experience performing production quality checks and maintaining accurate operating records.\n Ability to coordinate work assignments and communicate operational priorities effectively.\n Demonstrated ability to train, coach, and provide technical guidance to other employees.\n Strong organizational, problem-solving, and decision-making skills.\n Basic computer proficiency and ability to use electronic production systems.\n Effective verbal and written communication skills.\n Ability to work collaboratively with Production, Maintenance, FSQA, and other departments.\n Ability to perform the essential physical requirements of the position, with or without reasonable accommodation.\n Ability to work assigned shifts, overtime, and weekends as operational needs require.\n\nPreferred Qualifications\n\n Five or more years of experience in extrusion operations, preferably in dry pet food, animal feed, food, or similar manufacturing.\n Previous experience serving as a Production Lead, Lead Operator, or equivalent position.\n Experience training and onboarding manufacturing employees.\n Experience coordinating production schedules, employee assignments, and shift activities.\n Experience performing die changes, complex equipment setups, and product changeovers.\n Knowledge of extrusion processing parameters, including moisture, temperature, product density, and dimensional specifications.\n Experience using micrometers and other precision measuring devices.\n Familiarity with automated production systems, industrial controls, and process monitoring equipment.\n Experience participating in root cause analysis, process improvement, and equipment reliability initiatives.\n Familiarity with GMPs, food safety systems, and manufacturing quality requirements.\n\nKnowledge, Skills & Abilities\n\n Advanced understanding of extrusion equipment and dry pet food manufacturing processes.\n Strong leadership, communication, and team coordination skills.\n Ability to provide clear work direction, coaching, and technical guidance.\n Ability to independently perform complex equipment setups, adjustments, and troubleshooting.\n Strong mechanical, analytical, and problem-solving skills.\n Ability to prioritize production activities and respond effectively to changing operational requirements.\n Ability to monitor production performance and identify opportunities for improvement.\n Strong attention to detail when performing quality checks, measurements, and production documentation.\n Ability to communicate effectively with employees, supervisors, and cross-functional departments.\n Ability to maintain a professional and respectful work environment.\n Commitment to workplace safety, food safety, product quality, teamwork, and continuous improvement.\n\nWorkplace Safety\n\n Follow all company safety policies, procedures, and applicable regulatory requirements.\n Reinforce safe work practices and proper use of personal protective equipment among assigned production employees.\n Participate in required safety training and support safety discussions during shift meetings.\n Follow established machine guarding, equipment isolation, and Lockout/Tagout requirements.\n Perform equipment adjustments, cleaning, and maintenance activities only when properly trained and authorized.\n Identify and report unsafe equipment conditions, operating practices, and potential hazards.\n Assist with communicating safety concerns and implementing corrective actions within assigned authority.\n Maintain clean and organized production work areas.\n Immediately report unsafe conditions, near misses, injuries, and other workplace safety concerns.\n\nQuality & Food Safety\n\n Follow all applicable Good Manufacturing Practices, sanitation procedures, and food safety requirements.\n Reinforce compliance with established quality and food safety procedures among production employees.\n Ensure required product inspections, process checks, and quality documentation are completed accurately.\n Monitor critical processing parameters and report deviations from established specifications.\n Follow applicable Critical Control Point monitoring procedures where assigned and trained.\n Support proper product identification, traceability, and prevention of cross-contamination.\n Coordinate with FSQA regarding product deviations, quality concerns, and nonconforming materials.\n Follow established sanitation and equipment cleaning procedures.\n Support applicable BRCGS and company food safety management system requirements.\n Participate in mandatory food safety and quality training.\n Report food safety concerns and take appropriate action within assigned authority to protect product integrity.\n\nWork Environment & Physical R