Factory Manager - Masterbatch at شركة رائدة

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Job Description

Manage daily factory operations to achieve production plans safely, efficiently, and on schedule.
Convert monthly sales forecasts and confirmed orders into weekly and daily production plans.
Monitor production output by line, shift, product, grade, and batch.
Ensure compliance with approved formulations, processing parameters, and operating procedures.
Coordinate production priorities with sales, planning, procurement, warehouse, quality, and logistics teams.
Ensure accurate production reporting and timely entry of manufacturing data into the company’s ERP system.
Investigate production delays, capacity limitations, and operational bottlenecks and implement corrective actions.
Supervise single-screw and twin-screw extrusion lines, depending on the factory’s equipment.
Control feeding, mixing, compounding, extrusion, cooling, pelletizing, sieving, packing, and finished-product handling.
Monitor critical processing parameters, including:Extruder temperature profileScrew speed and torqueFeeding and dosing ratesMelt pressure and temperatureVacuum and venting conditionsCooling-water performancePelletizer speed and cutting qualityLine output and energy consumption
Extruder temperature profile
Screw speed and torque
Feeding and dosing rates
Melt pressure and temperature
Vacuum and venting conditions
Cooling-water performance
Pelletizer speed and cutting quality
Line output and energy consumption
Ensure correct machine setup and process conditions during grade changes and production start-ups.
Reduce start-up losses, color-change waste, contamination, black specks, inconsistent pellets, and unplanned stoppages.
Support troubleshooting of dispersion, agglomeration, moisture, feeding, pressure, pelletizing, and processing problems.
Supervise the production of:Calcium carbonate filler masterbatchPE- and PP-based filler masterbatchColor masterbatchWhite and black masterbatch, where applicablePVC compoundsCalcium carbonate-based plastic compoundsRecycled plastic compounds, where applicable
Calcium carbonate filler masterbatch
PE- and PP-based filler masterbatch
Color masterbatch
White and black masterbatch, where applicable
PVC compounds
Calcium carbonate-based plastic compounds
Recycled plastic compounds, where applicable
Ensure accurate weighing and dosing of calcium carbonate, polymers, pigments, waxes, processing aids, coupling agents, dispersing agents, and other additives.
Control formulation changes and ensure that unauthorized substitutions are not made.
Work with technical and quality teams to improve dispersion, processability, loading level, pellet quality, and product consistency.
Support industrial trials, product development, scale-up, and customer-specific production requirements.
Coordinate closely with Quality Control and Technical teams to ensure compliance with approved product specifications.
Ensure proper sampling, batch identification, traceability, testing, release, and retention-sample procedures.
Review quality results such as:Melt Flow IndexCalcium carbonate or ash contentMoistureDensity and bulk densityColor strength and color differencePigment and filler dispersionPellet size and uniformityBlack specks and contaminationMechanical and processing performance, where applicable
Melt Flow Index
Calcium carbonate or ash content
Moisture
Density and bulk density
Color strength and color difference
Pigment and filler dispersion
Pellet size and uniformity
Black specks and contamination
Mechanical and processing performance, where applicable
Investigate rejected batches, customer complaints, production deviations, and repeated quality problems.
Implement corrective and preventive actions and verify their effectiveness.
Ensure nonconforming materials are clearly identified, isolated, and controlled.
Coordinate preventive, predictive, and corrective maintenance with the maintenance team.
Monitor the condition of extruders, gearboxes, screws, barrels, feeders, mixers, pelletizers, cooling systems, compressors, dust collectors, and packing machines.
Analyze equipment failures and repeated downtime using root-cause analysis.
Plan maintenance activities to minimize disruption to customer orders.
Ensure critical spare parts are identified and available.
Monitor equipment condition and recommend repairs, upgrades, or capital investments when justified.
Monitor production cost per kilogram or metric ton.
Control polymer, calcium carbonate, pigment, additive, packaging, energy, and labor consumption.
Compare actual material consumption against approved bills of materials and standard consumption.
Reduce raw-material losses, off-specification batches, reprocessing, packaging waste, and production scrap.
Improve line productivity, production yield, and energy efficiency.
Identify and implement cost-saving initiatives without compromising product quality or safety.
Prepare regular variance reports covering output, consumption, waste, downtime, and production cost.
Coordinate raw-material requirements with procurement and warehouse teams.
Maintain appropriate stock levels for critical polymers, minerals, additives, pigments, and packaging materials.
Ensure proper storage and handling of calcium carbonate, polymers, pigments, additives, and finished products.
Apply FIFO or FEFO principles where appropriate.
Prevent material contamination, incorrect identification, moisture exposure, and unauthorized use.
Participate in stock counts and investigate production-related inventory variances.
Lead production supervisors, shift leaders, operators, helpers, and other factory personnel.
Establish clear responsibilities, shift structures, and performance expectations.
Assess workforce requirements based on production plans and equipment capacity.
Train employees on operating procedures, quality requirements, safety practices, and good housekeeping.
Evaluate employee performance and recommend training, development, recognition, or corrective action.
Build a culture of accountability, teamwork, discipline, problem-solving, and continuous improvement.
Ensure effective communication between shifts and departments.
Enforce company health, safety, environmental, and housekeeping requirements.
Ensure safe handling of powders, pigments, additives, polymers, hot surfaces, rotating machinery, and electrical equipment.
Ensure the correct use of personal protective equipment.
Control dust emissions and ensure ventilation and dust-collection systems operate effectively.
Participate in risk assessments, incident investigations, safety inspections, and emergency drills.
Ensure machine guards, emergency stops, fire-protection systems, and material-handling equipment remain operational.
Maintain factory areas according to 5S and good manufacturing practices.
Apply continuous-improvement tools to enhance output, quality, safety, and cost performance.
Use root-cause analysis, Pareto analysis, 5 Why, OEE, 5S, and other appropriate manufacturing tools.
Standardize successful processing conditions and best operating practices.
Prepare daily, weekly, and monthly factory performance reports.
Present production results, challenges, corrective actions, and improvement plans to senior management.
Support capacity planning, equipment selection, production-line expansion, and factory-development projects.

Requirements & Qualifications

Bachelor’s degree in Chemical Engineering, Production Engineering, Mechanical Engineering, Polymer Engineering, Materials Engineering, Industrial Engineering, or a related discipline.
Technical postgraduate studies, an MBA, or professional manufacturing certification would be an advantage.
Good command of written and spoken English.
Good computer skills, including Microsoft Excel and ERP or manufacturing-management systems.
Minimum8–20 years of relevant manufacturing experience, preferably in plastics compounding, masterbatch, or extrusion.
Minimum3–5 years in a production-management, operations-management, or factory-management position.
Proven experience managing production teams and shift-based manufacturing operations.
Practical experience with filler masterbatch, color masterbatch, calcium carbonate compounds, PE/PP compounds, PVC compounds, or recycled plastic compounds is highly preferred.
Experience in an export-oriented or quality-certified industrial company is an advantage.
Plastic extrusion and compounding processes
Single-screw and twin-screw extruders
Gravimetric and volumetric dosing systems
High-speed mixers and material-blending systems
Strand and underwater pelletizing systems, where applicable
PE, PP, PVC, recycled polymers, and related carrier resins
Calcium carbonate, coated calcium carbonate, pigments, waxes, dispersants, and processing additives
Masterbatch formulations and bills of materials
Pigment and filler dispersion
Color matching and color-difference control
Extrusion troubleshooting and process optimization
Production planning and capacity utilization
Preventive maintenance coordination
Quality-control procedures and batch traceability
Material-consumption analysis and cost control
Lean manufacturing, 5S, OEE, and root-cause analysis
ERP/MRP systems; experience with Odoo is an advantage
Strong leadership and team-management ability
Practical, hands-on manufacturing approach
Effective planning and prioritization
Strong analytical and problem-solving skills
Ability to make timely operational decisions
Cost awareness and commercial understanding
Effective communication across technical and nontechnical departments
Ability to manage pressure, changing priorities, and urgent customer orders
Strong discipline in documentation, reporting, and follow-up
Ability to coach, train, and develop production personnel
Filler masterbatch
Color masterbatch
Calcium carbonate compounds
Plastic extrusion and compounding
PE or PP masterbatch
PVC compounds
Cable compounds
Injection- or blow-molding compounds
Plastic recycling and recycled compounds
Industrial mineral processing
Polymer additives or pigment manufacturing
Responsible, disciplined, and results-oriented
Visible and engaged on the factory floor
Detail-focused without losing sight of overall business objectives
Ethical and consistent in applying company procedures
Calm and decisive when handling production problems
Proactive in identifying operational risks
Committed to safety, product quality, and customer satisfaction
Capable of building a stable, accountable production team

TalentIT Analysis

Quick Role Summary

Opportunity as "Factory Manager - Masterbatch" at شركة رائدة located in بني سويف on a Full-Time basis, suited for Fresh Graduate candidates. Key details from listing: • Manage daily factory operations to achieve production plans safely, efficiently, and on schedule. • Convert monthly sales forecasts and confirmed orders into…

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