Manager - Lamination (Extrusion)

Key Responsibilities:

1. Lamination and Extrusion Process Management:
• Oversee and manage the extrusion and lamination lines, ensuring smooth, efficient, and high-quality production processes.
• Ensure that all machines and equipment used in the lamination and extrusion processes are properly maintained and functioning efficiently.
• Supervise the extrusion of films, laminating different materials such as PP, BOPP, and polyester films.
• Develop and refine lamination and extrusion parameters to optimize film quality, output, and cost-effectiveness.
• Troubleshoot and resolve issues during the lamination or extrusion processes, including machine breakdowns, material inconsistencies, or quality issues.
2. Team Leadership & Development:
• Lead, supervise, and mentor a team of operators and technicians in the lamination and extrusion departments.
• Conduct performance evaluations, training, and skill development to improve team performance and ensure high production standards.
• Allocate resources and manage shifts effectively to meet production schedules while maintaining a high level of quality and safety.
• Promote a team culture of collaboration, continuous improvement, and safety.
3. Production Planning & Scheduling:
• Work with the production planning team to develop and execute detailed schedules for extrusion and lamination processes, ensuring timely delivery of finished products.
• Monitor and track production progress to ensure that deadlines are met, and resolve any delays or challenges promptly.
• Review and manage production orders to ensure that the required materials, machinery, and labor resources are available and optimized.
4. Quality Control & Assurance:
• Monitor and ensure that all products produced through the lamination and extrusion processes meet the established quality standards, including thickness, adhesion, clarity, and consistency.
• Implement quality control procedures and conduct periodic inspections to ensure product specifications are met.
• Collaborate with the Quality Control department to resolve any quality issues, implementing corrective actions as needed.
• Ensure that any defects or deviations from quality standards are recorded, analyzed, and addressed in a timely manner.
5. Process Optimization & Continuous Improvement:
• Identify opportunities for improving extrusion and lamination processes to increase output, improve quality, reduce waste, and lower operational costs.
• Implement process improvements and innovations based on performance data, feedback, and industry best practices.
• Analyze production data and implement corrective measures to reduce downtime, minimize scrap, and enhance overall productivity.
• Lead Kaizen or continuous improvement initiatives within the lamination and extrusion processes.
6. Safety Compliance:
• Ensure that all extrusion and lamination operations comply with the plants health, safety, and environmental regulations.
• Maintain a safe working environment for all team members, conducting regular safety audits and risk assessments to identify and mitigate potential hazards.
• Promote a culture of safety awareness and accountability within the team, providing ongoing training on safety procedures and best practices.
7. Equipment and Maintenance Management:
• Oversee the routine maintenance of extrusion and lamination machines, ensuring minimal downtime and extended equipment lifespan.
• Work with the Maintenance team to address any mechanical issues, ensuring quick resolution and reducing production interruptions.
• Monitor and manage spare parts inventory for the lamination and extrusion machines, ensuring that critical components are always available.
8. Cost Management:
• Develop and manage budgets for the lamination and extrusion departments, ensuring cost-effective operations.
• Track production costs, identifying areas for cost reduction and efficiency improvements.
• Work with the management team to optimize resource usage and minimize waste during the lamination and extrusion processes.
9. Collaboration with Other Departments:
• Collaborate with the R&D and Production teams to ensure that new materials, films, and coatings meet performance specifications for lamination and extrusion processes.
• Coordinate with the Procurement team to ensure the timely availability of high-quality raw materials and packaging films.

Desired Qualifications & Skills:

• Bachelor's degree in Mechanical Engineering, Chemical Engineering, Polymer Science, Materials Science, or a related technical field.
• Advanced certifications or a Master's degree in a relevant area (e.g., Polymer Engineering, Production Management) will be considered a plus.
• 7-10 years of experience in extrusion and lamination processes, preferably in the packaging industry, with at least 3-5 years in a supervisory or managerial role.
• Knowledge of regulatory requirements related to safety, environmental standards, and product compliance (e.g., FDA, REACH, BRC, 5S or other industry standards).
• Proficient knowledge of extrusion and lamination process parameters such as melt temperature, pressure control, die design, film thickness, coating techniques, etc.
• Expertise in film quality control techniques for lamination products, including testing for tensile strength, clarity, adhesion, and barrier properties.
• Experience with process optimization methodologies such as Lean Manufacturing, Six Sigma, or Kaizen to enhance production efficiency and reduce waste.
• In-depth experience working with extrusion machinery (e.g., multi-layer, cast, blown film extrusion) and lamination technologies (e.g., adhesive, thermal, co-extrusion, or multilayer lamination.
• Demonstrated expertise in managing large-scale production lines with a focus on operational efficiency, quality control, and machine troubleshooting.