JOB DESCRIPTION: PILGER OPERATOR1. Role Overview
The Pilger Operator is responsible for operating cold pilger mills to reduce tube diameter and wall thickness while maintaining strict dimensional tolerances, surface quality, and productivity targets. The role is critical to achieving consistent tube quality for HVAC, refrigeration, and industrial applications.
2. Key ResponsibilitiesMachine Operation
- Operate pilger mill (feed, rolling, and extraction cycles) as per defined pass schedule
- Set up tooling (dies, mandrels, saddles) as per product specification
- Ensure correct alignment and positioning before starting production
Process Control
- Follow approved pilger pass profile and reduction schedule
- Monitor:
- Diameter reduction
- Wall thickness consistency
- Surface finish
- Adjust feed rate, stroke rate, and lubrication as required
Quality Assurance
- Check tube dimensions using vernier, micrometer, and gauges
- Ensure compliance with internal specs and standards like ASTM
- Identify and prevent defects:
- Eccentricity
- Surface cracks
- Tool marks
- Thickness variation
Tooling Management
- Inspect dies and mandrels before and after use
- Report wear, damage, or mismatch immediately
- Ensure proper lubrication and cooling of tools
Material Handling
- Load mother tubes safely onto the machine
- Ensure correct tube ID/OD and heat number before processing
- Segregate finished, rejected, and rework material
Maintenance Support
- Perform routine checks (oil levels, lubrication, cooling system)
- Support maintenance team during breakdowns or changeovers
- Maintain machine cleanliness and 5S standards
Safety & Compliance
- Follow all safety protocols (PPE, machine guards, lockout/tagout)
- Ensure safe handling of heavy tubes and rotating equipment
- Maintain safe working environment around the machine
3. Key Performance Indicators (KPIs)
- Production output (tons/shift)
- Yield (%) and material recovery
- Rejection rate (%)
- Tool life (dies/mandrels)
- Machine uptime (%)
- Dimensional accuracy (Cp/Cpk if implemented)
4. Skills & CompetenciesTechnical Skills
- Understanding of cold pilgering process
- Ability to read process sheets and drawings
- Knowledge of OD/ID control and reduction ratios
- Familiarity with measuring instruments
Behavioral Skills
- Attention to detail
- Discipline in following process parameters
- Quick response to abnormalities
- Team coordination with QC and maintenance
5. Qualifications & Experience
- Education: ITI / Diploma in Mechanical or equivalent
- Experience:
- 2–5 years in pilger mill operation (preferably copper/alloy tubes)
- Experience in multi-stand or high-speed pilger mills preferred
6. Reporting Structure
- Reports to: Shift Supervisor / Production Incharge
- Coordinates with:
- Quality Control Team
- Maintenance Team
- Material Handling Team
7. Working Conditions
- Shop-floor environment (heat, noise, coolant exposure)
- Shift-based role (including night shifts)
- Requires physical handling and standing for long durations
Experience:
- Pilger Operating: 5 years (Required)
Work Location: In person
