Extrusion Machine Operator

Role & responsibilities

1. Machine Setup & Start-Up

• Prepare the extrusion line by setting temperature zones, screw speed, air pressure, vacuum, and cooling parameters.
  
• Install and align die head, mandrel, and corrugator mould blocks as per tube size.
  
• Load raw materials (PP/PE/PA granules, masterbatch) and verify drying/moisture levels.
  
• Ensure the machine is clean and free from previous material contamination before startup.
  

2. Production Operation

• Run the corrugated tube extrusion line smoothly to achieve target output.
  
• Maintain stable process parameters throughout the shift.
  
• Ensure uniform corrugation, consistent OD/ID, wall thickness, and crush strength.
  
• Monitor coil lengths, cutting accuracy, and proper packaging.
  

3. Quality Control & Inspection

• Conduct regular in-process checks:
  
• OD/ID
  
• Wall thickness
  
• Corrugation pitch & uniformity
  
• Colour consistency
  
• Tensile/crush resistance (as required)
  
• Identify defects early (ovality, pinholes, weak corrugation, die drool, bubbles, black specs) and take corrective action immediately.
  
• Record quality readings in the daily log sheet and inform QC of abnormalities.
  

4. Material & Wastage Management

• Follow BOM and standard process wastage (SPW) limits.
  
• Maintain proper mixing ratios for masterbatch and regrind.
  
• Ensure no overuse or underuse of raw materials beyond norms.
  
• Handle and store materials safely to avoid contamination or moisture absorption.
  

5. Mould Block & Die Changeovers

• Perform quick and accurate mould block changes for different tube sizes.
  
• Clean and maintain mould blocks, die head, and mandrel during changeovers.
  
• Minimise downtime by ensuring readiness of tools and parts.
  

6. Preventive Maintenance & Machine Care

• Conduct routine cleaning of die head, hopper, filter screens, and heaters.
  
• Check for leakages, loose bolts, abnormal vibrations, and wear.
  
• Coordinate with maintenance team for breakdowns or major repairs.
  
• Ensure lubrication schedules and safe machine operation.
  

7. Documentation & Reporting

• Maintain shift-wise production sheets, coil counts, raw material usage, and rejection logs.
  
• Update machine downtime entries with reasons.
  
• Report any deviations from standard parameters immediately to supervisor.
  

8. Safety & Compliance

• Follow all safety protocols: PPE, lockout/tagout, safe handling of heaters and rotating parts.
  
• Maintain 5S on the extrusion line: cleanliness, sorting, standard arrangement.
  
• Comply with IATF 16949:2016 and internal SOP requirements for automotive production.
  
• Ensure proper traceability of materials and finished goods.
  

9. Team Coordination

• Guide helpers during loading, unloading, and coil packing.
  
• Coordinate with QC for approvals and inspection.
  
• Work closely with the supervisor to meet daily and monthly production targets.
  

10. Continuous Improvement

• Suggest improvements in productivity, mould block change setup, material efficiency, and rejection reduction.
  
• Stay updated with new extrusion technologies (single-wall, double-wall, slit conduits).
  
• Maintain discipline, punctuality, and commitment to quality.
  

Preferred candidate profile

1. Work Experience

• 37 years

  of hands-on experience in

  PP/PE/PA corrugated tube extrusion lines

  , preferably automotive-grade.
• Experience with

  Chinese/Taiwanese corrugator machines

  (e.g., Zhongya, Italy-type corrugators) is strongly preferred.
• Must have operated:
  
• Die head + mandrel setup
  
• Corrugator mould blocks
  
• Auto cutter & coil winder
  
• Candidates who have worked in

  automotive wiring harness supplies

  or

  conduit manufacturing plants

  get priority.

2. Technical Expertise

• Strong understanding of

  extrusion temperature zones, screw speed, vacuum, air pressure, and cooling control

  .
• Ability to

  identify and troubleshoot defects

  independently:
• Oval tubes
  
• Wall thickness variation
  
• Die drool
  
• Weak corrugation
  
• Black specs
  
• Poor crush resistance
  
• Skilled in

  mould block changeovers

  within defined downtime.
• Knowledge of

  material behaviour

  (PP/PE/PA + masterbatch, regrind, moisture control).

3. Quality & Documentation

• Familiar with

  automotive quality parameters

  : OD/ID, crush strength, tensile strength, corrugation uniformity.
• Able to maintain accurate

  shift production reports

  ,

  material consumption logs

  , and

  QC inspection sheets

  .
• Exposure to

  IATF 16949, 5S, and internal SOP systems

  .

4. Behavioural Competencies

• Disciplined, reliable, and quality-focused

  — no shortcuts, no excuses.
• Ability to work

  12-hour shifts

  without compromising output quality.
• Strong communication with helpers, QC, and supervisors.
  
• Problem-solving mindset with readiness to

  take ownership of the line

  .
• Calm and stable temperament—able to handle pressure during breakdowns or urgent orders.
  

5. Physical & Practical Requirements

• Physically fit to handle

  mould block installation

  , cleaning, and machine supervision.
• Comfortable working in

  hot extrusion environments

  .
• Should not have habits that disrupt shift operations (late coming, excessive leaves, addiction issues).
  

6. Education

• ITI/Diploma in

  Plastics, Mechanical, Electrical

  , or relevant technical trade preferred.
• Non-ITI candidates with strong hands-on experience will also be considered.
  

7. Additional Advantage

• Experience in

  slit-type corrugated tubes

  (automotive-grade).
• Experience with

  Dorman-style export conduit specifications

  (bonus for your export project).
• Ability to follow

  English labels and numeric parameters

  on HMI screens.
• Exposure to

  basic preventive maintenance

  of extrusion equipment.