To lead and manage end-to-end extrusion operations for PVC and OPVC pipe manufacturing along with Post operations, Grinding Operations, Scrap Usages Management, ensuring optimum productivity, consistent product quality, cost control, and safe plant operations while driving process excellence and operational efficiency, people management and development for the Production system.
Lead and champion operations wide process improvement initiatives to achieve improved production processes, reduced wastage, and improved quality leading to improved efficiency at work. This role will play a pivotal role in driving Continuous Improvement initiatives at respective sites and also overall operation and maintenance of Extrusion including end to end people management and also dispatching the FG in due timeline ensuring safety of people and equipment. To focus on improving productivity by challenging the status quo and by implementing best practices in the shop floor.
Extrusion Production Management: Lead production operations for PVC and OPVC pipe extrusion lines including mixing, compounding, extrusion, calibration, cooling, cutting, socketing, and packing etc. Ensure achievement of daily, weekly, and monthly production targets with optimum machine utilization as per Plant KPI’s. Optimize extrusion parameters to run the lines at optimum capacity with high efficiency. Ensure smooth running of high-speed extrusion lines and socketing machines.
Process Optimization & Technology Control: Ensure proper control of PVC / CPVC dry blend formulations, additives, stabilizers, impact modifiers, and lubricants. Monitor melt flow stability, pipe wall thickness control, ovality, and dimensional accuracy as per BOM and the criteria guidelines as per QA standards. Manage OPVC pipe production process including biaxial orientation, stretching, and pressure control. Implement process improvements to enhance throughput by lean manufacturing practices.
Quality Assurance: Ensure compliance with BIS / ASTM / ISO standards for uPVC, CPVC and OPVC pipes. Monitor & know how impact on critical product quality parameters such as: Hydrostatic pressure test Impact strength Vicat softening temperature Density and wall thickness Socket strength and leak-proof performance Coordinate with QA team to address quality deviations and root cause analysis.
Productivity & Operational Excellence: Drive Lean Manufacturing, TPM, 5S, and Kaizen initiatives on shop floor. Improve Overall Equipment Effectiveness (OEE), line efficiency, and productivity. Reduce scrap, rejection, and start-up losses.
Maintenance Coordination: Work closely with maintenance and engineering teams. Develop and implement Autonomous maintenance programs for extrusion machinery to minimize downtime and ensure reliable operation. Preventive maintenance of extrusion lines Screw and barrel performance monitoring Die head maintenance Vacuum tank and cooling system optimization Minimize downtime and improve equipment reliability.
Raw Material & Cost Control: Manage consumption of PVC resin, compounds, impact modifiers, stabilizers, lubricants, and masterbatches. Ensure efficient material usage and cost optimization. Monitors regrind utilization and waste reduction.
Safety & Compliance: Ensure adherence to EHS standards and statutory compliance in manufacturing operations. Promote safe working practices in extrusion lines, mixing units, and material handling areas and shop floors.
Team Leadership & Development: Lead and mentor production engineers, supervisors, extrusion operators, and technicians. Develop a high-performance production culture with accountability and ownership. Conduct training on extrusion process control and quality standards. Evaluate new technologies and materials to enhance product performance and reduce manufacturing costs Prepare technical documentation for Audit (ISO 9001), including engineering drawings, specifications and reports in SAP. To lead for Zone leader of 5S as a lean management activity. Conducting Daily Safety Toolbox Talk with team members
Key Performance Indicators (KPIs): Achieving Predefined Targets, Extrusion Line Efficiency, Overall Equipment Effectiveness (OEE), Scrap / Rejection Rate , Raw Material Consumption Variance, BOM Control, SAP Vs Physical, Machine Downtime Reduction, Ensuring RM consumptions as per BOM, Safety Compliance, On-Time SKU’s Production/Delivery Order Fulfillment, Min SAP Vs. Phy Gap and Zero Non-Compliance -EHS & Labor in shop floor
With Overall Exp of 15-18 years with minimum 5-7 Years in Handling PVC Pipe Production
Degree – CIPET/Polymer Engineering/Plastic Engineering/B-Tech in Mechanical Engg, MBA in Operations.
Strong knowledge of pipe extrusion processes, equipment, and materials (e.g., PVC, HDPE).
Experience with process optimization, root cause analysis, and continuous improvement methodologies (TPM, 5S, Tool Box talk, Risk assessment, PTW, JHA).
Knowledge of SAP-PP Module must.
Excellent problem-solving skills and attention to detail.
Effective communication and interpersonal skills, with the ability to collaborate across teams.
Ability to manage multiple projects and prioritize tasks effectively.
Familiarity with industry standards and regulations related to pipe manufacturing.
