Production Planning & Management
- Plan, organize, and supervise daily, weekly, and monthly Blown Film production activities.
- Ensure production targets are achieved according to approved production plans.
- Prepare production schedules based on customer requirements, product specifications, machine capacity, and raw-material availability.
- Allocate machines, manpower, raw materials, and other production resources effectively.
- Monitor production progress against planned targets and take immediate corrective action when required.
- Ensure smooth production flow with minimum downtime, production loss, and unnecessary machine stoppage.
- Coordinate with Planning, Sales, Store, Quality, Maintenance, and other relevant departments to ensure uninterrupted production.
Blown Film Machine & Process Management
- Supervise the operation and performance of Blown Film Extrusion Machines.
- Ensure proper machine setup, startup, shutdown, product changeover, and process control.
- Monitor critical process parameters such as: Extrusion temperature Die temperature Melt temperature Extruder speed/RPM Screw speed Air pressure Bubble stability Cooling conditions Film thickness Width Line speed.
- Ensure production parameters are maintained according to approved product specifications.
- Monitor bubble formation, film gauge consistency, winding quality, and overall film appearance.
- Ensure proper control of machine settings during product changeovers.
- Identify process deviations and take timely corrective action.
- Improve machine operating practices to maximize productivity and minimize production losses.
Machine Performance & Maintenance Coordination
- Monitor the performance, operating condition, and efficiency of Blown Film machines and related equipment.
- Coordinate with the Engineering/Maintenance team for preventive, predictive, and breakdown maintenance.
- Minimize machine downtime and production interruptions.
- Identify recurring mechanical, electrical, heating, cooling, extrusion, die, winding, or other machine-related problems.
- Ensure timely troubleshooting and corrective action for machine-related issues.
- Support machine installation, commissioning, trial production, machine modification, and production ramp-up when required.
- Maintain proper records of machine downtime, breakdowns, repairs, and recurring technical problems.
- Work with Maintenance/Engineering teams to improve machine reliability and operating efficiency.
Production Efficiency & Productivity Improvement
- Monitor and improve: Production output, Machine efficiency, Machine utilization, Production speed, Capacity utilization, Downtime Wastage, Scrap Rejection, Rework Manpower productivity
- Develop and implement initiatives to increase production capacity and productivity.
- Identify bottlenecks in the production process and implement effective solutions.
- Improve machine utilization and reduce idle time.
- Optimize production parameters to achieve higher output without compromising quality.
- Establish and monitor production efficiency targets for machines and production teams.
Raw Material & Wastage Control
- Monitor the consumption and utilization of polymer/raw materials and production additives.
- Ensure proper material usage according to approved product specifications and formulations.
- Monitor raw-material consumption against standard/BOM or approved production requirements.
- Control production wastage, scrap, edge trim, startup loss, rejection, and rework.
- Analyze material consumption variance and take corrective action where necessary.
- Coordinate with Store, Planning, and Procurement teams to ensure timely availability of required raw materials.
- Ensure proper handling, identification, and storage of raw materials within the production area.
Quality Control
- Ensure Blown Film products meet approved quality standards and customer specifications.
- Work closely with the Quality Control/QA team to maintain consistent product quality.
- Monitor critical film-quality parameters, including: Thickness / Gauge, Width Transparency, Appearance Strength, Sealing performance where applicable, Surface quality, Bubble stability, Winding quality, Roll quality.
- Identify and resolve defects such as uneven thickness, gauge variation, wrinkles, bubbles, blocking, poor winding, contamination, surface defects, and other process-related issues.
- Analyze recurring production defects and conduct Root Cause Analysis (RCA).
- Implement corrective and preventive actions to reduce rejection and customer complaints.
- Ensure proper process control and adherence to approved specifications.
Manpower Management & Team Leadership
- Lead and supervise Production Supervisors, Technicians, Machine Operators, Helpers, and other production personnel.
- Prepare manpower allocation and shift schedules according to production requirements.
- Ensure adequate manpower availability for each production shift.
- Monitor employee productivity, discipline, attendance, and performance.
- Provide technical guidance and on-the-job coaching to operators and production personnel.
- Identify training requirements and develop the technical capabilities of the production team.
- Build a culture of discipline, accountability, teamwork, quality, safety, and continuous improvement.
- Ensure effective communication and coordination between shifts.
Problem Solving
- Lead the production team in resolving machine, process, quality, and production-related problems.
- Diagnose and troubleshoot recurring Blown Film production issues.
- Conduct Root Cause Analysis (RCA) for major or recurring problems.
- Develop and implement effective Corrective and Preventive Actions (CAPA).
- Take timely decisions to minimize production losses, downtime, wastage, and rejection.
- Escalate major technical issues to senior management and Engineering/Maintenance when required.
- Ensure lessons learned from major problems are documented and implemented.
Safety & Compliance
- Ensure all Blown Film production activities comply with company safety policies and applicable standards.
- Ensure operators follow proper machine operating procedures and workplace safety requirements.
- Ensure appropriate use of PPE in production areas.
- Identify production-area hazards and implement preventive measures.
- Ensure safe operation of extruders, heaters, cooling systems, compressors, winding equipment, and associated machinery.
- Promote a strong Safety-First culture within the production team.
- Report and take immediate action regarding unsafe conditions or incidents.
SOP, Process Control & Continuous Improvement
- Ensure proper implementation of production SOPs, work instructions, and standard operating parameters.
- Develop or improve SOPs where required in coordination with relevant departments.
- Standardize machine operating procedures to improve consistency.
- Identify opportunities for process improvement, productivity enhancement, and cost reduction.
- Promote 5S, Lean Manufacturing, Kaizen, and continuous improvement practices where applicable.
- Implement best practices to improve production stability and machine performance.
Production Reporting & Performance Analysis
- Prepare and review daily, weekly, and monthly production reports.
- Monitor and analyze key production indicators, including: Production Achievement, Machine Efficiency, Capacity Utilization Machine Downtime, Production Wastage, Scrap Rejection, Raw Material Consumption, Production Yield, Manpower Productivity, Machine Utilization, Production Cost
- Compare actual production performance against planned targets.
- Identify performance gaps and prepare improvement plans. Present production performance, major problems, corrective actions, and improvement initiatives to senior management.
