Operations Manager

preferably with 5+ years in Plastic Injection Moulding operations

Shubham - ( +91 9920532656 ) kindly share your resume on Watsapp Please do not call.

Job Summary

The Operations Manager Injection Moulding will be responsible for managing the day-to-day manufacturing operations of Avon Industries PLC, with primary responsibility for Injection Moulding production and coordination with Blow Moulding, Rotational Moulding, Tool Room, Maintenance, Quality, Stores and other supporting functions. The position will ensure production targets are achieved safely, efficiently, economically and on time, while maintaining product quality, machine availability, manpower productivity and minimum material wastage. The role will drive OEE improvement, downtime reduction, rejection reduction, mould utilization, preventive maintenance discipline and manufacturing cost optimization.

Primary Responsibility

1. Production & Operations Management

• Manage day-to-day production operations and ensure achievement of daily, weekly and monthly production targets.
• Prepare and execute machine-wise production plans based on customer requirements and delivery schedules.
• Optimize machine, mould and manpower utilization.
• Monitor actual production against planned quantities and take corrective action for shortfalls.
• Coordinate shift operations and ensure effective shift handovers.
• Identify production bottlenecks and implement corrective actions.
• Coordinate with Planning, Sales, Stores, Procurement, Quality and Maintenance for smooth production.

2. Injection Moulding Operations

• Manage Injection Moulding operations and ensure stable and efficient machine performance.
• Monitor and optimize injection pressure, injection speed, holding/packing pressure, temperature, cooling time, screw speed and cycle time.
• Ensure correct mould loading/unloading, machine setting, material feeding and start-up/shutdown procedures.
• Troubleshoot common injection moulding defects including flash, short moulding, sink marks, warpage, burn marks, black spots and dimensional variation.
• Drive cycle-time reduction and process parameter standardization.
• Ensure SOPs and process sheets are followed for every product and mould

3. Machines, Utilities & Equipment

• Manage Injection Moulding Machines, including hydraulic, servo-hydraulic and PLC/HMI-controlled equipment as applicable.
• Monitor auxiliary equipment such as hopper dryers, auto loaders, material mixers/blenders, chillers, mould temperature controllers, cooling towers, compressors, conveyors and granulators.
• Coordinate with Blow Moulding and Rotational Moulding operations as required.
• Work with Maintenance to improve machine availability and reliability.

4. OEE, Productivity & Continuous Improvement

• Establish and monitor machine-wise OEE, availability, performance and quality.
• Monitor cycle time, machine utilization, downtime, rejection, rework and material wastage.
• Lead downtime, changeover and productivity improvement initiatives. • Implement Lean Manufacturing, 5S, Kaizen, TPM, SMED, 5-Why, Fishbone and PDCA practices where applicable.

5. Quality & Process Control

• Ensure products are manufactured according to approved specifications and quality standards.
• Work closely with Quality to reduce rejection, rework and customer complaints.
• Monitor product weight, dimensions, colour, surface finish, strength, leakage and other critical parameters.
• Lead root-cause analysis and corrective/preventive actions for recurring defects.

6. Raw Material & Wastage Control

• Monitor consumption of PP, HDPE and other approved thermoplastic materials, masterbatch, additives and regrind where applicable.
• Control material usage against approved standards.
• Reduce scrap, rejection and unnecessary material loss.
• Ensure material traceability and correct mixing ratios.
• Review material consumption and variance reports.

7. Mould & Tool Room Coordination

• Coordinate mould availability, mould trials, mould changeovers and mould maintenance.
• Work closely with Avon's in-house Tool Room for preventive and corrective mould maintenance.
• Monitor mould condition, mould life and recurring mould-related defects.
• Ensure moulds are identified, maintained, stored and available as per production plans

8. Maintenance & Breakdown Management

• Coordinate preventive and breakdown maintenance with the Maintenance Department.
• Monitor machine breakdown hours, MTBF and MTTR.
• Conduct root-cause analysis for repeated mechanical, electrical, hydraulic, pneumatic and control-system failures.
• Identify critical spare-parts requirements and drive reduction of breakdown losses.

9. Manpower & Shift Management

• Plan manpower according to production schedules and machine loading.
• Manage Production Supervisors, Operators, Technicians and support staff.
• Prepare shift rosters and monitor attendance and productivity.
• Develop operator skills and ensure training on machines, SOPs, quality and safety

10. Cost Control & Energy Efficiency

• Control manufacturing cost through reduction of wastage, rejection, downtime and overtime.
• Monitor energy and utility consumption per kg/piece where applicable. • Improve machine loading and production efficiency.
• Identify opportunities to reduce consumable, maintenance and operating costs

11. Safety, 5S & Compliance

• Ensure strict adherence to factory safety procedures and PPE requirements.
• Promote machine, electrical and fire safety and safe material handling. • Ensure housekeeping and 5S standards are maintained.
• Ensure production targets never compromise employee or equipment safety.

12. MIS & Management Reporting

• Prepare daily, weekly and monthly production reports.
• Report production achievement, OEE, machine utilization, downtime, rejection, material wastage and labour productivity.
• Prepare machine-wise and shift-wise performance dashboards.
• Highlight production risks, bottlenecks and major deviations to management

Key Skills & Competencies

• Strong practical knowledge of Plastic Injection Moulding.

• Knowledge of Blow Moulding and Rotational Moulding is an advantage. • Strong understanding of moulds, plastic materials and process parameters.

• Knowledge of hydraulic, pneumatic, electrical and PLC/HMI systems.

• Strong knowledge of OEE, Lean Manufacturing, TPM, 5S and Kaizen.

• Production planning, manpower and shift management.

• Strong troubleshooting and root-cause analysis skills.

• Good knowledge of Microsoft Excel and production MIS.

• Strong communication, leadership and decision-making skills

Qualifications & Experience

• Bachelors degree in mechanical engineering, Production Engineering, Manufacturing Engineering, Industrial Engineering, Plastics/Polymer Engineering or a related technical discipline.
• Diploma holders with substantial relevant experience may also be considered.
• 815 years of overall manufacturing experience, preferably with 5+ years in Plastic Injection Moulding operations.
• Strong experience managing injection moulding machines, moulds, production teams and manufacturing KPIs.
• Experience in plastic household products, containers, furniture, tanks or similar products will be an advantage.
• Experience in Blow Moulding, Rotational Moulding and Tool Room coordination will be an advantage.

Key Attributes

• Hands-on and production-focused leadership style.

• Strong ownership and accountability.

• Excellent problem-solving and decision-making ability.

• High attention to quality, safety and production discipline.

• Ability to work under pressure and meet production deadlines.

• Analytical and data-driven approach.

• Strong team-building and communication skills.

• Proactive, self-motivated and results-oriented professional.