Role & Responsibilities
- Manage end-to-end extrusion operations for PVC, UPVC, CPVC, SWR and ASTM-standard pipes.
- Plan and execute daily/weekly production as per production schedules, customer requirements and dispatch priorities.
- Manage extrusion lines, including twin-screw extruders, dies, calibrators, vacuum sizing, cooling tanks, haul-offs and cutting systems.
- Optimize extrusion parameters such as temperature, screw speed, torque, pressure, vacuum, cooling and haul-off speed.
- Ensure achievement of production targets, OEE, productivity, yield and machine utilization.
- Monitor and control material consumption, scrap, rejection and process losses.
- Troubleshoot extrusion-related defects including dimensional variation, wall-thickness variation, ovality, surface defects, discoloration, poor fusion, cracks and brittleness.
- Ensure consistent product quality as per applicable BIS, ASTM and customer specifications.
- Coordinate with Quality, Maintenance, Tool Room and Stores teams to ensure uninterrupted production.
- Drive preventive maintenance, breakdown reduction and optimum performance of extrusion machines, dies and tooling.
- Manage manpower deployment, operator performance, shift planning and skill development.
- Establish and maintain SOPs, process parameters, work instructions and quality checkpoints for extrusion operations.
- Lead 5S, Kaizen, TPM, Lean Manufacturing and continuous improvement initiatives.
- Analyze production, downtime, rejection, scrap and productivity data and implement corrective actions.
- Identify bottlenecks and improve line speed, changeover time, yield and overall equipment effectiveness.
- Ensure compliance with plant safety, housekeeping, PPE and operational standards.
- Prepare and present daily/weekly/monthly extrusion performance reports to the Plant Head/Factory Head.
- Lead, train and develop extrusion supervisors, operators and technicians.
Skills Required
- 10–15 years of relevant experience in PVC/UPVC/CPVC/plastic pipe extrusion manufacturing.
- Strong hands-on experience with twin-screw extrusion technology.
- Good knowledge of PVC, UPVC and CPVC formulations, processing parameters and material behaviour.
- Strong understanding of extrusion dies, mandrels, calibrators, vacuum tanks, cooling systems, haul-offs and cutters.
- Ability to independently set, optimize and troubleshoot extrusion process parameters.
- Good knowledge of PVC, UPVC, CPVC, SWR and ASTM pipe specifications and quality requirements.
- Strong understanding of pipe dimensional parameters including OD, ID, wall thickness, weight, length and ovality.
- Experience in handling multiple extrusion lines and large production teams.
- Strong knowledge of OEE, yield, rejection, scrap, downtime and productivity analysis.
- Good troubleshooting skills for extrusion, tooling, material and process-related problems.
- Experience in production planning, capacity utilization and manpower management.
- Knowledge of Lean Manufacturing, 5S, Kaizen and TPM.
- Strong coordination skills with Quality, Maintenance, Tool Room, Stores and Production Planning teams.
- Strong analytical, problem-solving and decision-making abilities.
- Diploma/B.E./B.Tech in Mechanical, Plastics, Polymer, Production or related engineering discipline preferred.
To apply for this job email your details to aman.yadav@praxisconsultants.in