Shift Engineer - Extrusion

Watertec; Coimbatore District; On-site; INR 600,000 - 800,000; Full time

Job summary

Watertec in Tamil Nadu seeks an experienced Extrusion Shift Engineer to lead CPVC, UPVC and RPVC pipe extrusion operations. You will supervise the shift, manage manpower, control processes, ensure quality, monitor performance, and drive safety and continuous improvement.

The role requires hands-on expertise in extrusion lines, die setting, machine start-up/shutdown, and OEE improvement, with a focus on maintaining product quality and production targets.

Qualifications

• Hands-on knowledge of CPVC, UPVC and RPVC pipe extrusion processes.
• Good knowledge of PVC materials and extrusion lines.
• Experience in die setting, machine start-up/shutdown, changeover, calibration, vacuum, cooling and haul-off 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.
• Ability to read engineering drawings, die designs and technical documents.
• 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 in a shift-based manufacturing environment and meet production targets.

Responsibilities

• Supervise extrusion machine operators, technicians and helpers during the shift.
• Allocate manpower and responsibilities to meet production and quality targets.
• Train operators on extrusion operation, process parameters, quality and safety.
• Coordinate with Production, Quality, Maintenance, Stores and other departments for smooth shift operations.
• Operate and monitor CPVC, UPVC and RPVC pipe extrusion lines for productivity and efficiency.
• Monitor barrel/die temperature, screw speed, pressure, throughput, vacuum, cooling, haul-off speed and line speed.
• Ensure start-up/shutdown, changeover, and process stabilization.
• Maintain shift production reports, process records and downtime reports.
• Take corrective actions to minimize losses and improve line efficiency.
• Monitor quality parameters and troubleshoot defects in collaboration with Quality Control.
• Ensure proper die setting, cleaning and maintenance; supervise auxiliary equipment like mixers, feeders, chillers, compressors and conveyors.
• Ensure safe operation and PPE usage; conduct regular safety and 5S checks.
• Drive process improvement: productivity, yield, quality, OEE and lean initiatives.

Skills

CPVC, UPVC, RPVC extrusion

PVC materials and extrusion lines

Die setting and start-up/shutdown

Extrusion parameters control

Troubleshooting and quality issues

Engineering drawings and specs

OD/ID and dimensional control

Supervisory and manpower management

OEE and Lean manufacturing

Shift-based manufacturing

Tools

Twin-screw extruders

Extrusion dies

Temperature controllers

Vacuum systems

Job description

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.