Operator

About this role

Job Summary The Finishing Line Operator is responsible for operating, synchronizing, and monitoring integrated soap/detergent finishing equipment, including three-roll mill, vacuum plodder/extruder, rotary/flying cutter, die stamper, primary flow wrapper, and carton packing machinery. The position ensures seamless line synchronization, bar weight consistency, precise stamping embossing, tight wrapping, and optimal throughput while adhering to ISO 14001, ISO 45001, 5S workplace organization, and Kaizen principles. DUTIES AND RESPONSIBILITIES OPERATING PARAMETERS & PROCESS CONTROL Machine Operating Parameters Monitored: Monitor roll temperatures/gaps on three-roll mill, vacuum level (bar/mmHg) and barrel/die temperatures on plodder, cutting length/speed, stamper die chilling temperature and stamping pressure, flow-wrap sealing jaw temperature, film tension, and pack line speed. Authorized Process Adjustments: Authorized to make fine adjustments to cutter length/speed to control bar weight, adjust stamper die cooling fluid flow, regulate wrapper film tension, and adjust sealing jaw temperature. Process Adjustments Requiring Prior Approval: Major speed changes altering line balance, die geometry changes, wrapper sensor bypass, or modifications to plodder screw speed outside validation windows require Production Lead/Supervisor approval. Stop-Work / Stop-Machine Authority: Empowered to instantly stop the finishing line in case of severe bar jamming, die damage risks, persistent weight off-spec, wrapper seal burn-through, mechanical pinch hazard, or safety guard interlock failure. Additional Duties: Any other duty which may be assigned on time-to-time basis. MACHINE SYNCHRONIZATION, CHANGEOVER & SETUP Line Machine Synchronization: Actively manage and maintain speed synchronization between extruding plodder, cutter, stamper, and wrapper to prevent bar accumulation, deformation, weight variation, and excessive recycle scrap. Changeover & Setup Procedure: Execute complete size/die changeover, adjust guide rails, change wrapping film rolls, replace stamper dies, perform thorough machine cleaning, and verify first-piece inspection prior to launching full production run. Autonomous Operator Preventive Maintenance: Perform daily cleaning of plodder barrel, mill rolls, stamper dies, and wrapper sealing jaws; inspect and tension drive chains/belts; check vacuum pump oil level; lubricate slide bearings. Maintenance Department Exclusions: Plodder screw replacement, vacuum pump mechanical overhauls, heater band wiring, electronic drive parameter programming, and complex mechanical timing adjustments are strictly reserved for Maintenance Troubleshooting & First-Level Corrective Action: Identify bar cracking, die sticking, misshaped bars, or wrapper misregistration; execute first-level remedies (e.g., adjust die chilling temperature, clean die surface, adjust eye-mark tracking sensor). Technical Escalation Route: Vacuum Pump / Mechanical Drives -> Maintenance; Wrapper Temperature/Sensor Failures -> Electrical/Automation; Persistent Bar Cracking/Deformation -> QCA / Production Supervisor. QUALITY CONTROL, OEE & DATA RECORDING Technical Quality Checks & Acceptance Limits: Conduct hourly checks for bar weight uniformity, bar hardness, stamping logo clarity, seal integrity, and package print legibility against established acceptance criteria. OEE & Downtime Tracking: Track line OEE including total units produced, net running hours, speed losses, scrap/re-plodded material weight, and downtime categorized by standardized reason codes (e.g., film change, die cleaning, jam, upstream feed delay). QUALITY CONTROL, OEE & DATA RECORDING Technical Quality Checks & Acceptance Limits: Conduct hourly checks for bar weight uniformity, bar hardness, stamping logo clarity, seal integrity, and package print legibility against established acceptance criteria. OEE & Downtime Tracking: Track line OEE including total units produced, net running hours, speed losses, scrap/re-plodded material weight, and downtime categorized by standardized reason codes (e.g., film change, die cleaning, jam, upstream feed delay). ENVIRONMENT, HEALTH & SAFETY (ISO 14001:2015 & ISO 45001:2018) EMS & OHSMS Implementation & Improvement: Implement, document, maintain and continually improve the Environmental Management System (ISO 14001:2015) and Occupational health and safety management system (ISO45001:2018). ISO 14001:2015 Environmental Compliance: Minimize packaging film waste and plastic scrap during roll changeovers; collect and segregate recyclable film, cardboard, soap re-plod scraps, and waste oil; prevent detergent powder dispersion into plant surroundings ISO 45001:2018 Occupational Health & Safety: Strictly enforce machine guarding and interlock protection on high-speed cutter, three-roll mill pinch points, and stamper presses; execute LOTO during die changing and jaw cleaning; wear required PPE (cut-resistant gloves, safety footwear, ear protection). EHS Hazard Mitigation: Inspect safety light curtains and emergency stop buttons daily prior to operation; report any mechanical nip point or electrical safety hazards immediately. WORKPLACE ORGANIZATION (5S) & CONTINUOUS IMPROVEMENT (KAIZEN) 5S Workplace Implementation: Maintain 5S standards along the entire finishing and packing line: Sort unnecessary packaging items, Set in Order changeover tools/dies on visual shadow boards, Shine machines and conveyance belts daily, standardize changeover checklists, Sustain clean line conditions. Kaizen & Continuous Improvement: Participate in SMED (Single-Minute Exchange of Die) initiatives to accelerate product changeovers, suggest Kaizen improvements to eliminate soap scrap, optimize wrapper film utilization, and eliminate micro-stoppages