Plastics Thermoforming Manager

Job Description

Job Description

Thermoforming Manager

Location: DeKalb, IL
Schedule: Day shift (7:00 AM–4:00 PM, flexible)
Reports to: VP of Operations

About the Company

This organization has over 40 years of experience in thermoforming and heat-seal packaging solutions. They design and manufacture custom thermoformed packaging (blisters, clamshells, trays), sealing machinery, tooling, and automation systems. The team supports customers end-to-end—from concept and design through engineering, prototyping, build, installation, and ongoing support.

The culture is hands-on and team-oriented. Leaders wear multiple hats, decisions move quickly, and there is little red tape. The company is in a growth phase and is investing in leadership to support long-term stability and improvement.

Position Overview

This is a newly added Thermoforming Manager role created to support growth and split responsibilities with an existing manager. While the current manager focuses on daily operations and urgent issues, this role will be more focused on production control, process optimization, quality, and continuous improvement .

The ideal candidate enjoys being on the manufacturing floor, solving problems, and driving improvements in a small-company environment where impact is visible and immediate.

Key Responsibilities

Daily Production Control

• Lead daily production meetings and set priorities for forming, trimming, and stacking lines
• Balance labor, machine capacity, tooling, and changeovers
• Ensure on-time production while minimizing scrap and downtime
• Manage shift handoffs and communicate issues across crews

Thermoforming Process Management

• Set and optimize forming parameters (sheet heat zones, plug assist timing, vacuum/pressure, cooling)
• Troubleshoot issues such as webbing, thin corners, haze, warpage, and trim misalignment
• Optimize cycle times while maintaining part quality and tool life
• Validate repeatable setups and standard work

Tooling & Equipment

• Coordinate mold installs, changeovers, and qualifications
• Partner with maintenance and toolroom on repairs and improvements
• Support mold trials, first-article runs, and new tool approvals
• Track mold performance and lifecycle

Quality & Compliance

• Ensure packaging meets customer specifications
• Support audits and customer visits
• Lead root cause analysis for scrap, defects, and complaints

Materials & Scrap Control

• Monitor resin usage and regrind ratios (PET, RPET, APET, PP, PS)
• Reduce scrap from startups, changeovers, and trim operations

Leadership & Safety

• Lead two shift supervisors and support operators and team leads
• Enforce safety programs including lockout/tagout and hot-sheet safety
• Manage attendance, performance, hiring, and development

Continuous Improvement

• Drive improvements in OEE, yield, scrap reduction, and labor efficiency
• Implement Lean, 5S, and standardized work

Reporting & Collaboration

• Track KPIs including OEE, scrap %, downtime, and labor efficiency
• Collaborate with Engineering, Quality, Maintenance, Sales, and Supply Chain

Qualifications

Required

• 2+ years of leadership or management experience in manufacturing
• Thermoforming or plastics packaging experience
• Strong troubleshooting and process optimization skills
• Comfortable wearing multiple hats in a small-company setting

Preferred

• 4+ years of plant or operations leadership
• Plastics packaging industry background
• Lean / 5S / continuous improvement experience
• Bachelor’s degree in Engineering or related field (not required)
• Bilingual English/Spanish

Compensation & Benefits

• Salary range: $100,000–$120,000
• Medical, Dental, Vision
• 401(k) with match
• 9 paid holidays
• 3 weeks PTO
• Climate-controlled facility
• Clear path for growth into broader plant leadership