Job Description

Job Title: Production Manager - PICC & Copper Extrusion Process

Reporting To:

Plant Head

Department:

Production

Role Summary

The Production Manager - PICC & Copper Extrusion Process is responsible for driving efficient, safe, and high-quality production of paper insulated copper conductors (PICC) and copper extrusion output at Vidya Wires Limited's manufacturing facility. This role requires deep technical knowledge of conductor manufacturing processes, strong leadership, planning expertise, and hands-on execution skills to meet daily production targets, process quality standards, and continuous improvement goals.

Key Responsibilities

1. Production Planning & Execution

Plan, organize, and control end-to-end manufacturing activities for PICC and copper extrusion lines. Prepare and implement daily/weekly production schedules, ensuring timely delivery against orders. Coordinate with planning, procurement, and inventory teams for raw material (copper, paper insulation, resins) availability. Ensure optimum utilization of manpower, machines, and materials to achieve planned output with minimum waste and scrap.

2. Process & Technical Operations

Oversee the PICC manufacturing process, including copper conductor preparation, paper insulation application, impregnation/heat treatment (if applicable), and final sizing. Manage copper extrusion operations, ensuring correct extrusion parameters (temperature, speed, die profile, lubrication) for consistent product quality. Drive strict process parameter control and standardization to maintain tight tolerances and reduce defects. Trouble-shoot production bottlenecks and technical issues, liaising with engineering and maintenance teams to resolve root causes.

3. Quality Assurance & Compliance

Ensure production meets ISO / BIS / industry and customer specifications for PICC. Coordinate with Quality Control for in-process inspections (dimensions, insulation integrity, surface finish) and final product testing. Implement corrective and preventive actions (CAPA) for defects and quality deviations. Maintain production records, test certifications, and quality documentation for audits and compliance.

4. Safety, Environment & Compliance

Champion EHS (Environment, Health & Safety) compliance and maintain a zero-accident mindset on the shop floor. Enforce proper PPE use, safe operating practices, housekeeping, and adherence to ISO standards. Ensure compliance with statutory requirements and environmental norms.

5. Team Leadership & Development

Lead, mentor, and supervise production supervisors, technicians, and operators. Build training plans, skill matrices, and competency development initiatives for production teams. Drive accountability for performance metrics, productivity, and team engagement.

6. Continuous Improvement & Efficiency

Implement Lean Manufacturing, Kaizen, 5S, and other continuous improvement methodologies. Monitor production KPIs -- OEE, downtime, capacity utilization, yield -- and act to optimize output. Propose and deliver process improvements that reduce cycle time, cost, energy use, and defects.

7. Maintenance & Asset Care

Collaborate closely with the maintenance team for preventive, predictive, and breakdown maintenance planning. Minimize unplanned downtime of PICC lines and extrusion equipment through robust planning. Participate in equipment commissioning and upgrades.

8. Reporting & Documentation

Prepare and submit daily/weekly/monthly production reports and performance dashboards to senior management. Maintain SOPs (Standard Operating Procedures), work instructions, shift logs, and production data.

Qualifications

Bachelor's degree in mechanical / production / electrical engineering (B.E./B. Tech) or equivalent. Strong technical background in copper manufacturing processes.

Experience

10-15 years of progressive experience in wire & conductor manufacturing -- ideally including PICC and copper extrusion segments. Prior experience supervising production in a high-volume manufacturing environment.

Skills & Competencies

Deep understanding of copper conductor manufacturing and extrusion workflows. Strong leadership, communication, and team development skills. Good analytical, planning, and organizational skills. Experience with ERP systems (MS Dynamics BC 365) for production planning and reporting. Hands-on approach to process optimization and problem solving. * Knowledge of quality and safety systems such as ISO standards and BIS specifications.