Production Manager (Blown Film Machine)

Job Description

Title: Production Manager (Blown Film Machine)

Company Name: Royal Weaving and Coating Industries Ltd.

Vacancy: 02

Age: At most 45 years

Job Location: Narayanganj

Salary: Negotiable

Experience:

• 8 to 10 years
• The applicants should have experience in the following business area(s): Plastic/ Polymer Industry, Packaging Industry

• Bachelor's Degree or Diploma in Mechanical Engineering, Industrial & Production Engineering, Polymer Technology, Plastics Technology, Chemical Engineering or a related technical discipline.

• Relevant technical qualifications with substantial practical experience in Blown Film production may also be considered.

• 8 to 10 years
• The applicants should have experience in the following business area(s): Plastic/ Polymer Industry, Packaging Industry

• Age At most 45 years
• Only Male

• Minimum 3–5 years of experience in a Production Manager/Assistant Production Manager/Senior Production role is preferred.

• Strong practical experience in Blown Film Extrusion Machine operation and production management is essential.

• Experience with LDPE, LLDPE, HDPE, or similar polymer film production will be highly preferred.

• Practical knowledge of extrusion processes, machine setup, process parameters, troubleshooting, quality control, and maintenance coordination is essential.

• Experience in managing production teams and achieving production targets is required.

• RFL Group | Akij Group | Meghna Group | Leera Group or other established and reputed manufacturing companies work experience will be given high preference.

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

6. 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).

· mplement corrective and preventive actions to reduce rejection and customer complaints.

· Ensure proper process control and adherence to approved specifications.

7. 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.

8. 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.

9. 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.

10. 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.

11. 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.

• Lunch Facilities: Partially Subsidize
• Salary Review: Yearly

• Accommodation facility

• Festival Bonus : 1 Full Salary