Job Title: Production Manager – PICC & Copper Extrusion Process
Reporting To: Plant Head
Department: Production
Role Summary
The Production Manager – PICC & Copper Extrusion Process is responsible for driving efficient, safe, and high-quality production of paper insulated copper conductors (PICC) and copper extrusion output at Vidya Wires Limited’s manufacturing facility. This role requires deep technical knowledge of conductor manufacturing processes, strong leadership, planning expertise, and hands-on execution skills to meet daily production targets, process quality standards, and continuous improvement goals.
Key Responsibilities
1. Production Planning & Execution
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Plan, organize, and control end-to-end manufacturing activities for PICC and copper extrusion lines.
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Prepare and implement daily/weekly production schedules, ensuring timely delivery against orders.
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Coordinate with planning, procurement, and inventory teams for raw material (copper, paper insulation, resins) availability.
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Ensure optimum utilization of manpower, machines, and materials to achieve planned output with minimum waste and scrap.
2. Process & Technical Operations
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Oversee the PICC manufacturing process, including copper conductor preparation, paper insulation application, impregnation/heat treatment (if applicable), and final sizing.
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Manage copper extrusion operations, ensuring correct extrusion parameters (temperature, speed, die profile, lubrication) for consistent product quality.
- Drive strict process parameter control and standardization to maintain tight tolerances and reduce defects.
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Trouble-shoot production bottlenecks and technical issues, liaising with engineering and maintenance teams to resolve root causes.
3. Quality Assurance & Compliance
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Ensure production meets ISO / BIS / industry and customer specifications for PICC.
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Coordinate with Quality Control for in-process inspections (dimensions, insulation integrity, surface finish) and final product testing.
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Implement corrective and preventive actions (CAPA) for defects and quality deviations.
- Maintain production records, test certifications, and quality documentation for audits and compliance.
4. Safety, Environment & Compliance
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Champion EHS (Environment, Health & Safety) compliance and maintain a zero-accident mindset on the shop floor.
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Enforce proper PPE use, safe operating practices, housekeeping, and adherence to ISO standards.
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Ensure compliance with statutory requirements and environmental norms.
5. Team Leadership & Development
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Lead, mentor, and supervise production supervisors, technicians, and operators.
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Build training plans, skill matrices, and competency development initiatives for production teams.
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Drive accountability for performance metrics, productivity, and team engagement.
6. Continuous Improvement & Efficiency
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Implement Lean Manufacturing, Kaizen, 5S, and other continuous improvement methodologies.
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Monitor production KPIs — OEE, downtime, capacity utilization, yield — and act to optimize output.
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Propose and deliver process improvements that reduce cycle time, cost, energy use, and defects.
7. Maintenance & Asset Care
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Collaborate closely with the maintenance team for preventive, predictive, and breakdown maintenance planning.
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Minimize unplanned downtime of PICC lines and extrusion equipment through robust planning.
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Participate in equipment commissioning and upgrades.
8. Reporting & Documentation
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Prepare and submit daily/weekly/monthly production reports and performance dashboards to senior management.
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Maintain SOPs (Standard Operating Procedures), work instructions, shift logs, and production data.
Qualifications
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Bachelor’s degree in mechanical / production / electrical engineering (B.E./B. Tech) or equivalent.
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Strong technical background in copper manufacturing processes.
Experience
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10–15 years of progressive experience in wire & conductor manufacturing — ideally including PICC and copper extrusion segments.
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Prior experience supervising production in a high-volume manufacturing environment.
Skills & Competencies
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Deep understanding of copper conductor manufacturing and extrusion workflows.
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Strong leadership, communication, and team development skills.
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Good analytical, planning, and organizational skills.
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Experience with ERP systems (MS Dynamics BC 365) for production planning and reporting.
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Hands-on approach to process optimization and problem solving.
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Knowledge of quality and safety systems such as ISO standards and BIS specifications.
