PDC supervisor

1. Job Purpose

To supervise and control day-to-day Pressure Die Casting (PDC) operations to ensure achievement of production targets, product quality, machine efficiency, safety, and minimum rejection. The PDC Supervisor is responsible for managing manpower, monitoring casting parameters, ensuring proper machine operation, and coordinating with Quality, Maintenance, and other departments to achieve smooth production.

2. Key Responsibilities

A. Production Planning and Execution

• Execute daily production plans as per the schedule provided by the Production Manager.
• Ensure achievement of daily production targets while maintaining required quality standards.
• Allocate operators and helpers to machines according to production requirements.
• Monitor machine-wise production, cycle time, downtime, and output.
• Ensure availability of dies, raw materials, consumables, and other production requirements.
• Coordinate with planning and stores departments to avoid production interruptions.

B. Pressure Die Casting Process Control

• Supervise PDC machine operations and ensure compliance with approved process parameters.
• Monitor critical parameters such as metal temperature, die temperature, injection speed, injection pressure, holding pressure, cycle time, and cooling time, as applicable.
• Ensure proper die setting, machine setting, and start-up approval before regular production.
• Monitor molten metal handling, metal feeding, and metal cleanliness as per established procedures.
• Ensure proper use of release agents, lubricants, cooling systems, and other process consumables.
• Verify that operators follow approved operating instructions and standard operating procedures.
• Coordinate die changes, trial runs, and process adjustments with authorized personnel.

C. Quality Control and Rejection Reduction

• Ensure production components meet approved drawings, specifications, and quality standards.
• Coordinate with the Quality Department for first-piece approval and routine inspections.
• Monitor common casting defects such as porosity, blowholes, cold shuts, misruns, flash, cracks, shrinkage, and dimensional deviations.
• Identify abnormal rejection trends and take immediate containment action.
• Ensure segregation and identification of rejected, rework, and accepted components.
• Support root cause analysis and corrective and preventive actions for recurring defects.
• Ensure that process changes are made only with proper authorization and verification.

D. Manpower Management

• Allocate duties to operators, helpers, and other production personnel.
• Monitor attendance, punctuality, discipline, and work performance.
• Train operators on machine operation, process parameters, defect identification, and safe working practices.
• Ensure adequate manpower availability for each shift.
• Promote teamwork, productivity, and adherence to company policies.

E. Machine, Die, and Equipment Maintenance

• Conduct routine checks of PDC machines, dies, trimming presses, and auxiliary equipment.
• Coordinate preventive maintenance and die maintenance with the Maintenance and Tool Room departments.
• Report machine breakdowns, hydraulic issues, cooling failures, and other abnormalities immediately.
• Monitor downtime and ensure timely escalation of breakdowns.
• Ensure machines and dies are operated within approved limits to prevent damage.
• Maintain records of breakdowns, die usage, maintenance requirements, and production stoppages.

F. Safety and Housekeeping

• Ensure strict compliance with machine safety procedures and PPE requirements.
• Ensure safe handling of molten metal and adherence to hot-metal safety precautions.
• Verify that machine guards, interlocks, emergency stops, and safety devices are functional.
• Ensure safe operation of ladles, metal handling equipment, trimming presses, and lifting devices.
• Maintain 5S, housekeeping, and clear access to workstations and emergency exits.
• Immediately report unsafe conditions, near misses, and accidents.
• Ensure that operators do not bypass safety interlocks or perform unauthorized machine adjustments.

G. Documentation and Reporting

• Maintain daily production reports, shift reports, rejection reports, and downtime records.
• Record machine-wise production quantities, cycle times, and process parameters as required.
• Maintain records of raw material consumption, scrap generation, and process losses.
• Monitor and report production efficiency, rejection percentage, and machine utilization.
• Ensure proper shift handover, including pending production, breakdowns, quality issues, and maintenance requirements.
• Maintain applicable process checklists and records for internal and customer audits.

H. Coordination with Other Departments

• Coordinate with Quality for product inspection, defect analysis, and corrective actions.
• Coordinate with Maintenance for machine breakdowns and preventive maintenance.
• Coordinate with Tool Room for die repair, die trials, and die-related issues.
• Coordinate with Stores for raw materials, consumables, and spare parts.
• Inform the Production Manager about production delays, quality issues, and resource requirements.

Pay: ₹25,000.00 - ₹33,000.00 per month

Benefits:

• Food provided
• Paid sick time
• Provident Fund

Work Location: In person