XPS Manufacturing & Process Engineering Manager

About Kingspan Insulation, North America

Kingspan Insulation, North America, is part of the global Kingspan Group, a leader in high-performance insulation and building envelope solutions. Known for our commitment to innovation, sustainability, and superior building performance, Kingspan is transforming how the built environment performs—delivering solutions that meet and exceed energy efficiency, fire safety, and environmental goals.

At Kingspan, we don’t just build products—we pioneer technologies that shape the future of construction. Our culture is built around bold thinking, collaboration, and continuous improvement, creating an environment where people are empowered to lead and innovate.

Position Summary

The XPS Manufacturing & Process Engineering Manager is a key strategic leader responsible for the end-to-end ownership of Kingspan’s extruded polystyrene (XPS) manufacturing operation. This role combines hands-on operational leadership with deep technical oversight and direct ownership of R&D for the XPS product line.

This individual will be accountable for delivering safe, efficient, and innovative manufacturing outcomes, while also driving research and development initiatives that optimize formulations, enhance product performance, and ensure sustainable manufacturing practices. They will serve as the technical and operational authority on XPS production—blending long-term vision with day-to-day execution across manufacturing, engineering, and innovation functions.

Key Responsibilities

Leadership & Strategic Ownership

• Own and lead the full XPS manufacturing process from raw material handling to finished goods.
• Serve as the primary leader responsible for XPS process engineering and all related R&D functions.
• Develop and execute a long-term strategic roadmap for XPS manufacturing excellence and product innovation.
• Lead cross-functional collaboration across R&D, Supply Chain, Quality, Commercial, and EHS teams to align product performance, production goals, and sustainability targets.

R&D And Innovation

• Lead all research and development activities for XPS, including formulation, prototyping, testing, and scale-up.
• Drive the development of new materials and processing techniques to improve product performance, cost-effectiveness, and environmental impact.
• Translate R&D innovations into scalable, production-ready solutions in alignment with commercial strategy.
• Evaluate and implement new technologies, automation opportunities, and smart manufacturing practices that enhance competitiveness.

Process & Operations Excellence

• Optimize manufacturing processes for maximum efficiency, yield, and consistency.
• Implement best practices in process control, quality assurance, and root cause analysis.
• Drive continuous improvement through Lean, Six Sigma, or other structured methodologies.
• Monitor production KPIs and use data to make informed decisions that improve safety, output, and resource utilization.

Team Leadership & Development

• Build, lead, and mentor a team of process engineers, technicians, and operators dedicated to XPS operations.
• Foster a culture of accountability, innovation, and technical excellence.
• Ensure team alignment with Kingspan’s values of integrity, innovation, and collaboration.

Compliance & Safety

• Ensure all operations adhere to applicable safety, environmental, and quality standards.
• Maintain documentation and audit readiness for regulatory and internal requirements.

Qualifications

• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a related field (required); Master’s degree preferred.
• Minimum of 7 years of experience in manufacturing, including at least 3 years in polymer extrusion or a related field; direct experience with XPS is highly desirable.
• Demonstrated success in leading both manufacturing operations and R&D or product development initiatives.
• Deep technical knowledge of extrusion processes, polymer chemistry, and continuous manufacturing systems.
• Proven track record of driving innovation and implementing scalable process improvements.
• Strong leadership skills with the ability to influence and collaborate across multiple disciplines and organizational levels.
• Experience with Lean, Six Sigma, or other structured problem-solving and process improvement tools.
• Familiarity with sustainability initiatives in manufacturing is a plus.