Plant Manager – uPVC Profile Extrusion Plant

Position Summary:

The Plant Manager will be responsible for end-to-end management of the extrusion plant operations covering production, maintenance, manpower, planning, quality control, safety, compliance, and cost efficiency. This position requires strong technical expertise in polymer extrusion, leadership capability, and hands-on operational management to ensure consistent output and continuous improvement.

Key Responsibilities:

1. Production & Operations Management

· Plan, schedule, and execute daily, weekly, and monthly production activities as per order requirements and dispatch priorities.

· Manage multiple extrusion lines (Twin-Screw Conical Extruders, Co-extruders, Downstream Calibration, Haul-offs, Cutting & Stacking).

· Ensure optimum machine utilization, reduce downtime, and achieve production KPIs such as OEE (Overall Equipment Efficiency), yield, and productivity.

· Coordinate with Planning, Sales, and Dispatch departments to align production with sales requirements.

· Ensure the production of profiles in required dimensions, shades, and grades as per customer and project specifications.

1. Process Control & Optimization

· Monitor extrusion process parameters such as temperature, pressure, calibration, puller speed, and vacuum control.

· Ensure adherence to standard operating procedures (SOPs) and formulation control.

· Identify process bottlenecks and implement corrective actions for cycle time reduction, waste minimization, and process efficiency improvement.

· Work closely with R&D/Technical team for new die trials, formulation improvements, and new product development.

1. Quality Assurance & Control

· Enforce in-process and final product quality checks to maintain consistent product standards.

· Collaborate with QC team to ensure compliance with company specifications and customer requirements.

· Investigate quality deviations and customer complaints, conduct root cause analysis, and implement CAPA (Corrective and Preventive Actions).

· Maintain documentation for quality audits, certifications, and compliance inspections.

1. Maintenance & Engineering Management

· Supervise preventive, predictive, and breakdown maintenance of extrusion machines, vacuum tanks, chillers, compressors, material conveying systems, and DG sets.

· Develop and implement maintenance schedules in coordination with the maintenance team.

· Maintain equipment logs, spares inventory, and AMC (Annual Maintenance Contracts) where applicable.

· Ensure timely calibration of instruments and upkeep of utilities such as electrical panels, water-cooling systems, and dust collection units.

1. Manpower Planning & Team Development

· Manage a team of shift engineers, supervisors, operators, helpers, and maintenance technicians.

· Conduct manpower planning for all three shifts ensuring smooth plant operations.

· Foster a culture of accountability, performance orientation, and continuous learning.

· Conduct regular performance reviews, identify training needs, and ensure skill enhancement of the team.

· Enforce plant discipline, attendance, and adherence to company policies.

1. Material Management & Inventory Control

· Oversee receipt, storage, and consumption of raw materials such as PVC resin, stabilizers, lubricants, pigments, and calcium carbonate.

· Coordinate with stores and purchase departments for timely availability of raw materials and packing materials.

· Implement FIFO (First In, First Out) and control wastage and rejections.

· Maintain optimal stock levels of raw materials, WIP, and finished goods.

1. Cost Control & Efficiency Improvement

· Monitor and control variable and fixed costs such as power, manpower, and consumables.

· Analyze production data to identify areas of energy savings, productivity improvement, and scrap reduction.

· Implement lean manufacturing, 5S, TPM, and Kaizen practices.

· Support budgeting, forecasting, and monthly cost reviews with management.

1. Safety, Health & Environmental Compliance

· Ensure plant compliance with all statutory regulations under the Factories Act, Pollution Control Board, Fire Safety, and Electrical Safety norms.

· Conduct safety training, mock drills, and ensure proper use of PPE.

· Identify and mitigate potential risks through proactive safety management.

· Maintain records related to EHS (Environment, Health & Safety) and statutory audits.

1. Reporting & Documentation

· Prepare and present daily, weekly, and monthly MIS reports on production, downtime, quality, and manpower.

· Maintain detailed logs of extrusion parameters, shift reports, maintenance activities, and raw material usage.

· Coordinate with management on capital investments, equipment upgrades, and expansion projects.

1. Strategic Contributions

· Contribute to strategic planning for capacity expansion and technology upgradation.

· Evaluate new machinery, tooling, and automation solutions for long-term productivity enhancement.

· Represent the plant in management meetings and audits.

Required Qualifications & Experience:

· Education:

o B. Tech / B.E. / Diploma in Mechanical, Polymer, or Production Engineering.

· Experience:

o Minimum 8–10 years in plastic extrusion manufacturing (preferably uPVC profiles, pipes, or extrusion polymer).

o At least 2 years in a leadership or production head or assistant plant head role managing a medium- to large-scale extrusion facility.

· Technical Expertise:

o Strong knowledge of twin-screw extrusion process and equipment.

o Experience in extrusion die setup, calibration, and downstream systems.

o Understanding of uPVC formulation chemistry and process behaviour.

o Familiarity with mixing systems, material handling, and in-house recycling setups.

Key Skills & Competencies:

· Leadership and People Management

· Analytical and Problem-Solving Skills

· Strong Communication and Reporting Ability

· Planning, Coordination & Decision-Making

· Knowledge of ERP / SAP for production tracking

· Proficiency in MS Office (Excel, Word, PowerPoint)

· Commitment to Quality and Continuous Improvement

Work Environment & Reporting:

· Reports To: Managing Director

· Location: Factory, Kolkata (Full-time, On-site)

· Working Hours: 6 days a week, with 2-shift operational oversight

Compensation & Benefits:

· Competitive salary as per industry standards

· Performance-based incentives

· Provident Fund, ESI, Gratuity as applicable

· Accommodation support (if required)

· Two – Wheeler vehicle support

· Opportunity to lead modernization and capacity expansion projects

Job Types: Full-time, Permanent

Pay: ₹90, ₹150,000.00 per month

Application Question(s):

• What is your current location?
• Do you have experience in plastic extrusion manufacturing (preferably uPVC

profiles, pipes, or extrusion polymer)

Work Location: In person