SUMMARY:
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POSITION INFO:
To lead, manage, and optimize all extrusion operations within the flexible packaging manufacturing environment, ensuring the safe, efficient, and cost-effective production of high-quality films that meet customer specifications. The HOD Extrusion is responsible for delivering production targets, driving continuous improvement, managing people and resources, and maintaining world-class manufacturing standards. Key Responsibilities Production Management Lead and oversee all blown film and\/or cast film extrusion operations Ensure production schedules are executed in line with customer demand and planning requirements Monitor production output, machine efficiency, and shift performance Optimize machine utilization and capacity planning Ensure adherence to production standards, recipes, and operating procedures Coordinate with planning, printing, laminating, slitting, and dispatch departments to achieve operational objectives Process Control and Optimization Monitor and control extrusion process parameters including: Melt temperature Extrusion pressure Die settings Gauge control Line speed Cooling systems Resin blends Ensure film thickness consistency and product conformance Lead process improvement initiatives to improve productivity and quality Conduct root cause analysis for process deviations and performance losses Drive reduction of waste, edge trim, start-up scrap, and downtime Quality Management Ensure all extruded products meet customer specifications and quality requirements Monitor key quality attributes including: Film thickness Tensile strength Haze and clarity Coefficient of friction (COF) Printability requirements Support customer approvals and quality audits. Implement corrective and preventive actions for quality concerns Work closely with the Quality Department to ensure compliance with ISO, BRCGS, and customer standards Leadership and People Management Lead, coach, and develop extrusion supervisors and operators Establish a high-performance culture focused on safety, quality, and productivity Conduct performance reviews and employee development plans Identify training needs and competency gaps Manage employee relations, attendance, discipline, and grievance matters in accordance with company policies Promote employee engagement and teamwork Safety, Health and Environmental Compliance Ensure full compliance with Occupational Health and Safety regulations Promote a zero-harm safety culture Conduct regular risk assessments and workplace inspections Ensure safe handling and storage of raw materials and chemicals Investigate accidents, incidents, and near-misses Implement corrective actions to prevent recurrence Ensure compliance with environmental standards and waste management procedures Maintenance and Asset Management Partner with the Maintenance Department to maximize equipment reliability Support preventive and predictive maintenance programs Monitor machine performance and address recurring breakdowns Participate in equipment upgrades and capital expenditure projects Improve machine uptime and Overall Equipment Effectiveness (OEE) Cost and Inventory Management Manage departmental budgets and operational costs Monitor raw material consumption including resins, additives, masterbatches, and recycled materials Reduce waste and improve material yield Control overtime and labour costs Ensure accurate inventory management and reporting Continuous Improvement Lead Lean Manufacturing, TPM, Six Sigma, and operational excellence initiatives Identify opportunities for automation and process enhancements Implement best practices to improve productivity and quality Develop and track departmental improvement projects Benchmark performance against industry standards Customer and Audit Support Support customer visits, technical reviews, and product trials Participate in internal and external audits Ensure compliance with food packaging, hygiene, and customer-specific requirements where applicable Assist in new product development and commercialization initiatives Key Performance Indicators (KPIs) Production output achievement (%) Overall Equipment Effectiveness (OEE) Film waste and scrap reduction (%) Downtime reduction (%) Yield efficiency (%) First Pass Quality (FPQ) Customer complaints Cost per kilogram produced On-time delivery support Safety incident frequency rate Labour productivity Training and competency compliance Minimum Qualifications Education Degree or Diploma in: Mechanical Engineering Chemical Engineering Industrial Engineering Polymer Science Packaging Technology Production Management Related Technical Field Experience Minimum 8-10 years' experience in plastics extrusion or flexible packaging manufacturing Minimum 5 years in a supervisory or management role within extrusion operations Strong experience in blown film and\/or cast film extrusion processes Experience within flexible packaging manufacturing is essential Experience with food-grade packaging production will be advantageous Technical Competencies Blown Film Extrusion Cast Film Extrusion Polymer Processing Resin and Masterbatch Technology Flexible Packaging Manufacturing OEE and Productivity Management Lean Manufacturing Six Sigma Methodologies Root Cause Analysis Statistical Process Control (SPC) Quality Management Systems TPM (Total Productive Maintenance) Production Planning and Scheduling ERP\/MRP Systems Occupational Health and Safety Management Working Conditions Manufacturing and production environment Exposure to high temperatures, moving machinery, and industrial noise Standing and walking for extended periods Occasional shift support and weekend work Frequent interaction with production, quality, maintenance, supply chain, and technical teams
