Shift Engineer - Extrusion

Job Summary:

We are looking for an experienced Extrusion Shift Engineer with hands-on experience in CPVC, UPVC and RPVC pipe extrusion. The candidate will be responsible for shift production, manpower management, process control, quality, machine performance, troubleshooting, safety, and continuous improvement.

Key Responsibilities:

1. Shift Supervision & Team Management

• Supervise extrusion machine operators, technicians, and helpers during the shift.
• Allocate manpower and responsibilities to achieve production and quality targets.
• Monitor team performance and ensure compliance with SOPs, company policies, and safety procedures.
• Train operators on extrusion machine operation, process parameters, quality, and safety.
• Coordinate with Production, Quality, Maintenance, Stores, and other departments for smooth shift operations.

2. Production & Process Management

• Operate and monitor CPVC, UPVC and RPVC pipe extrusion lines for optimum productivity and efficiency.
• Monitor and control critical parameters such as barrel/die temperature, screw speed, pressure, throughput, vacuum, cooling, haul-off speed, and line speed.
• Ensure efficient machine start-up, shutdown, product changeover, die change, and process stabilization.
• Monitor production output, raw material consumption, scrap, rejection, and machine downtime.
• Maintain accurate shift production reports, process records, and downtime reports.
• Take corrective actions to minimize production losses and improve line efficiency.

3. Quality Control & Troubleshooting

• Ensure pipes meet required quality standards, specifications, dimensions, and customer requirements.
• Monitor critical parameters such as OD, ID, wall thickness, weight, ovality, appearance, surface finish, and dimensional stability.
• Work closely with Quality Control to identify and resolve process and product quality issues.
• Troubleshoot extrusion defects such as dimensional variation, uneven wall thickness, ovality, surface defects, bubbles, black spots, discoloration, poor fusion, die lines, and inconsistent output.
• Adjust process parameters to maintain consistent product quality and production stability.

4. Machine, Die & Auxiliary Equipment

• Monitor the condition and performance of extruders, dies, heaters, temperature controllers, gearboxes, drives, vacuum systems, cooling tanks, haul-offs, and cutting machines.
• Assist Maintenance in troubleshooting machine, die, electrical, hydraulic, vacuum, and cooling system breakdowns.
• Ensure proper die setting, cleaning, inspection, and maintenance.
• Monitor auxiliary equipment such as mixers, feeders, chillers, compressors, grinders, and material conveying systems.
• Support preventive maintenance and promptly report abnormal machine conditions.

5. Safety & Housekeeping

• Ensure safe operation of extrusion machinery and compliance with all safety procedures.
• Ensure proper use of PPE by all team members.
• Conduct regular safety, 5S, and housekeeping checks.
• Report and address unsafe conditions, accidents, near misses, and equipment hazards.
• Maintain a clean, organized, and safe production environment.

6. Process Improvement & OEE

• Identify opportunities to improve productivity, yield, quality, OEE, and machine utilization.
• Analyze downtime, scrap, rejection, material consumption, and production losses.
• Implement corrective and preventive actions to improve line performance.
• Support 5S, Kaizen, Lean Manufacturing, Six Sigma, and continuous improvement initiatives.
• Work with Process/Engineering teams to optimize extrusion parameters and reduce process variation.

Key Skills Required

• Strong hands-on knowledge of CPVC, UPVC and RPVC pipe extrusion processes.
• Good knowledge of PVC materials, twin-screw extruders, extrusion dies, and pipe extrusion lines.
• Experience in die setting, machine start-up/shutdown, changeover, calibration, vacuum, cooling, haul-off, and cutting operations.
• Strong understanding of extrusion parameters: temperature, pressure, screw speed, line speed, throughput, vacuum, cooling, and material feeding.
• Ability to troubleshoot machine, die, material, process, and pipe quality issues.
• Knowledge of extrusion auxiliary equipment including mixers, feeders, chillers, compressors, grinders, and material conveying systems.
• Ability to read and understand engineering drawings, die designs, technical documents, and process specifications.
• Strong knowledge of OD, ID, wall thickness, weight, ovality, and dimensional control.
• Good supervisory, manpower handling, communication, coordination, and decision-making skills.
• Knowledge of OEE, production reporting, scrap/rejection reduction, 5S, Kaizen, and Lean Manufacturing.
• Ability to work effectively in a shift-based manufacturing environment and achieve production, quality, and efficiency targets.