Head of Department (HOD) – Extrusion

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

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