Packing Design Expert

Position: Packing Design Expert
Designation: Asst Manager / Manager
Location: Abu Road, Rajasthan
Industry: Ceramic / Composite Insulator Manufacturing
Experience: 8 to 15 Years

1. Job Purpose
   To design, lead and optimize the packing operations of electrical/ceramic insulators by ensuring safe, damage-free, efficient and cost-effective packing of finished products. The position will be responsible for developing suitable packing methods, improving packaging quality, reducing transit damages and ensuring timely dispatch as per customer and project requirements.
2. Key Responsibilities
   A. Packing Process Management

• Manage end-to-end packing activities for finished insulators before dispatch.
• Design, develop and standardize packing methods for different types, sizes and designs of insulators.
• Ensure proper selection and use of packing materials such as wooden crates, pallets, corrugated sheets, thermocol/foam, separators, protective films, straps, etc.
• Ensure proper protection of critical areas such as porcelain bodies, sheds, cemented portions, metal fittings, flanges and hardware.
• Establish standard packing specifications and Work Instructions (WIs) for different products.

B. Damage Prevention & Quality

• Analyse packing-related product damages occurring during handling, loading and transportation.
• Identify root causes of transit/handling damages and implement corrective and preventive actions.
• Work closely with Quality, Production, Stores, Dispatch and Engineering to minimize packing-related defects and customer complaints.
• Establish inspection checkpoints before final packing and dispatch.
• Ensure products are adequately secured against vibration, impact, moisture, dust and movement during transportation.

C. Packaging Development

• Develop innovative and cost-effective packing solutions for new and existing insulator products.
• Design/modify crates, pallets, separators and protective arrangements based on product dimensions and weight.
• Evaluate packaging materials and vendors for quality, durability and cost.
• Conduct trials for new packing designs and validate their effectiveness.
• Prepare packaging standards for domestic as well as export shipments.

D. Cost Optimization

• Monitor packing material consumption and identify opportunities for cost reduction.
• Reduce material wastage, rework and excess packaging.
• Optimize crate/pallet size and material utilization without compromising product safety.
• Develop reusable/returnable packaging solutions wherever feasible.
• Track and improve packing cost per insulator / per dispatch / per ton, as applicable.

E. Dispatch & Logistics Coordination

• Coordinate with Dispatch/Logistics teams to ensure safe loading and transportation of packed material.
• Ensure proper loading sequence and weight distribution inside trucks/containers.
• Verify lashing, strapping and securing arrangements before vehicle release.
• Ensure compliance with customer-specific packing and dispatch requirements.
• Support export packing requirements including containerization and moisture protection.

F. SOP, Documentation & Systems

• Prepare and maintain:

• Packing SOPs

• Work Instructions

• Packing standards

• Packaging specifications

• Inspection checklists

• Material consumption standards

• Packing BOMs

• Packaging drawings

• Maintain records of packing material consumption, damages and improvement initiatives.

• Develop visual standards and photographs for correct packing practices.

G. Team Management & Training

• Lead and supervise packing operators/workmen.
• Define manpower requirements and optimize packing manpower.
• Train workers on correct packing methods, handling practices and safety requirements.
• Ensure adherence to 5S, PPE and workplace safety standards.
• Conduct regular skill development and refresher training for packing personnel.

3. Key Performance Indicators (KPIs)

• Reduction in transit/packing-related damages
• Packing rejection/rework %
• Packing material cost per unit
• Packing material consumption vs. standard
• Material wastage %
• Dispatch adherence / On-time dispatch
• Customer complaints related to packing
• Packaging development and cost-saving initiatives
• Productivity per packing manpower
• Compliance with packing SOP/WI
• 5S and safety compliance

4. Required Technical Competencies

• Strong knowledge of industrial packaging and material handling.
• Experience in packing of heavy, fragile and high-value electrical/ceramic products.
• Knowledge of wooden crate/pallet design and fabrication.
• Knowledge of cushioning, separators, strapping, lashing and load securing.
• Understanding of transportation and transit damage mechanisms.
• Ability to read product drawings and understand dimensions/weights.
• Basic knowledge of AutoCAD for packaging/crate drawings will be preferred.
• Knowledge of packaging material specifications and testing.
• Strong problem-solving and RCA/CAPA skills.
• Knowledge of Lean Manufacturing, Kaizen, 5S and TPM will be an advantage.

5. Desired Industry Experience
   Candidates from industries involving fragile/heavy industrial products will be preferred, such as:

• Electrical Insulators
• Composite Insulators
• Transformer / Electrical Equipment
• Ceramic Products
• Heavy Engineering
• Switchgear
• Power Transmission Equipment
• Industrial Components
• Export-oriented manufacturing
• Glass / Sanitaryware / Technical Ceramics

6. Behavioral Competencies

• Strong ownership and accountability
• Hands-on approach
• Problem-solving ability
• Good coordination with cross-functional teams
• Team leadership
• Cost-conscious approach
• Attention to detail
• Customer-focused mindset
• Ability to work under dispatch pressure
• Continuous improvement mindset

7. Educational & Experience Criteria
   Qualification: Graduation & PG Diploma in Packaging Technology from Indian Institute of Packaging.
   Experience: 8 to 15 years of relevant experience in industrial packing/packaging, preferably with experience in packing fragile, heavy or high-value products.
   Preferred: Candidates having experience in developing packing solutions for large-size ceramic/electrical insulators and export shipments.
8. Job Scope
   The selected candidate will be expected to establish a robust and standardized packing system for the insulator plant, with primary focus on:
   Zero Damage Standardized Packing Optimum Packing Cost Safe Handling Timely Dispatch Customer Satisfaction