Senior Production Supervisor
Interplast Co. Ltd
Total years of experience :15 years, 1 Months
Established in 1981 for plastics converting, Interplast is a leading manufacturer in middle east of PVC compounds for a wide range of applications as well as finished products like electrical cable management systems, underground cable protection system, film & bags, flexible packaging & thermo-formed products
Role:
Supervise the operations of the manufacturing lines of the film and bags division of the company comprising of:
Blown film extrusion lines: mono-layer and multi-layerblown film of materials: LDPE, LLDPE, HDPE, PP, Metallocene PE, Advanced Polyolefins and PVC; Polyolefin (POF) heat shrink film extrusion (double bubble process); PVC blown film extrusion for cling film, twist film and heat shrink film
Flexograhic printing: Coordinate with printing section for planning and scheduling of blown film jobs for Flexographic printing. It include up to 10 color print including process print.
Bag making: Side & bottom sealing, patch & loop handle, bag-on-roll, wicket & round bottom, shirt type
Product range: Lamination grade film, FFS film, protective film, shrink film, shrink hood, pallet covers, warning & duct tapes, construction roll, shopping bags, diaper bags, courier bags and ice, poultry & bakery bags.
Team Size: Approx. 80 members.
Production Volume: Approx. 800 MT per month.
Responsibilities:
Production Management
Participate in development and implement of departmental goals and targets aligned to the overall company business objectives.
Deal with production planning, scheduling and control for achieving production targets with optimum loading of production lines with product mix as per sales plan.
Develop estimates for monthly requirements of raw materials based on sales forecasts and follow up with procurement for ensuring supplies for uninterrupted production.
Monitor manufacturing process; ensure efficient operations, troubleshoot the process and maintenance issues.
Develop, implement and update departmental policies and procedures ensuring smooth, efficient and safe operations of the plant.
Formulate, review and update standard operating procedures (SOP) for all shop floor activities including manufacturing, handling of raw materials and finished products and machine maintenance.
Prepare work instructions for new machines to define and standardize operating procedures to maintain predefined process parameters and product quality/yield.
Ensure implementation of and compliance with all applicable environmental, health and safety policies and procedures to achieve all EHS goals and objectives.
Deliver optimum support in requirements for outsourced services, negotiate contracts to obtain best value for approved budgets and administer contractors ensuring on time delivery and minimizing risks.
Evaluate annual performance of subordinate and recommend for revision to ensure their values.
Supervise and manage the departmental team promoting teamwork and providing training to improve performance and productivity.
Develop and manage production data, conducting regular review and analysis to identify variances and implement improvement action plans.
Supervised overall production and quality control of 3 sections:
Polyethylene blown film extrusion (co-extrusion process) - mono-layer and multi-layer polyethylene films
POF heat shrink film extrusion (co-extrusion, double bubble process) - polyolefin heat shrink films
PVC blown film extrusion - PVC cling film and twist film (single bubble process), PVC heat shrink film (double bubble process)
Led plant setup, development and implementation of production procedures for the POF heat shrink film (double bubble process) plant and earned management appreciation.
Led plant setup, development and implementation of production procedures for PVC cling film plant (single bubble process) and PVC heat shrink film (double bubble process).
Highlights:
Product Development
Participated in and contributed to all major product development projects - down-gauged heat shrink film for automated packaging lines, surface protective films, FFS Film, outer bags for chips and lamination grade film
Quality Improvements
Reduced customer complaints on a year-on-year basis and improved customer satisfaction levels.
Delivered substantial savings by reducing quality rejections on a year-on-year basis
Process Improvements
Managed manufacturing operations and achieved 100% fulfillment of sales demands during Ramadan during 2015, 2016, 2017, 2018 and 2019
Achieved over 98% of target volume production in all major categories and established new volume production benchmarks in several categories.
Revised the standard operating procedure (SOP) for make-ready of lines for setup and job changeover and reduced scrap generation
Implemented process improvements which increased machine efficiency in the blown film extruder section
Increased team productivity by over 15% through on-the-job training, teambuilding, development and deployment of personnel.
Delivered cost savings through optimum utilization of generated process scrap for suitable products.