Captain Machine Operator

9 hours ago

Hyderabad, Telangana, India Pragati Rrd Full time ₹ 5,00,000 - ₹ 25,00,000 per year

Job Summary:

The Captain (Master Operator) is the highest-level machine operator on the production floor, responsible for complete ownership of the machine's performance, including operation, setup, troubleshooting, optimization, and team guidance. The Captain acts as the technical expert for a specific machine or process line, especially where fully automatic and HMI-based equipment is involved.

This role is critical for ensuring maximum uptime, quality output, and continuous improvement in machine performance and team capability.

Role & responsibilities :

Mastery in Machine Operation:

  • Independently operate and manage fully automatic machines with advanced HMI (Human-Machine Interface) systems.
  • Fine-tune machine settings and process parameters to optimize quality and efficiency.
  • Handle complex machines such as high-speed packaging lines, CNCs, robotic arms, or automated inspection systems.

Technical Expertise & Troubleshooting:

  • Diagnose and resolve mechanical, electrical, pneumatic, and software-level issues.
  • Interpret HMI alarm logs, PLC data, and technical manuals for advanced troubleshooting.
  • Collaborate with the maintenance team on preventive and corrective maintenance.

Process Control & Quality:

  • Own the quality of the output monitor defect trends and lead corrective actions.
  • Lead root cause analysis (RCA) for recurring issues.
  • Use SPC, gauges, and quality tools to ensure compliance with product specs.

Process Optimization:

  • Identify and implement process improvements to reduce cycle time, waste, and downtime.
  • Analyse machine OEE (Overall Equipment Effectiveness) and take steps to improve it.
  • Suggest and lead small Kaizens, 5S, and lean initiatives.

Team Mentoring & Support:

  • Act as technical mentor for OP1, OP2, and OP3.
  • Train new operators on machine operation, HMI navigation, quality procedures, and safety.
  • Provide daily direction and monitor performance of the operator team on the assigned machine/line.

Documentation & Reporting:

  • Maintain accurate records of machine settings, downtime logs, shift reports, and product data.
  • Input and review data in HMI systems, SCADA dashboards, or production software.
  • Support audits, validations, and machine trials.

Safety Leadership:

  • Ensure strict adherence to machine safety SOPs, interlocks, and emergency procedures.
  • Lead safety drills or participate in safety audits.
  • Report incidents, conduct hazard assessments, and implement controls.

Preferred candidate profile

Educational Requirements:

  • Bachelor's degree in Printing Technology, Mechanical Engineering, or a related field.
  • Certifications or specialized training in printing processes, especially UV and 1 over 1 perfecting, is a plus.

Experience:

  • Minimum 5 years of experience in the printing industry, with at least 2 years in a supervisory role.
  • Experience with UV or 1 over 1 perfecting printing processes is highly preferred.
  • Experience in both UV and 1 over 1 perfecting printing is strongly preferred.
  • Experience working in rotational Shifts

Technical Skills:

  • In-depth knowledge of printing machines, UV curing systems, and 1 over 1 perfecting printing processes.
  • Strong troubleshooting and problem-solving skills related to printing machinery.
  • Ability to manage machine maintenance, production efficiency, and quality assurance.

Soft Skills:

  • Strong leadership, team management, and communication skills.
  • Ability to work under pressure and meet tight deadlines.
  • Strong attention to detail and organizational skills.

CTC: As per market standards

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