Specialist - Flat or Round Cable Manufacturing

Job Title: Specialist - Flat or round Cable manufacturing - Extrusion machine operation

Job Summary:

Flat cable & Round cable manufacturing and assembly operations

Key Result Areas (Accountability & Responsibility of the role)

• Lead by example, ensuring a safe and efficient working environment across all flat cable manufacturing and assembly operations.
• Independently manage and monitor PVC extrusion machine operations, ensuring consistent coating of copper conductors with PVC insulation.
• Ensure achievement of daily production targets for 6, 8, 10, 12, 24 and 64-core flat cable configurations.
• Establish, monitor and control critical extrusion parameters, including temperature zones, screw speed, line speed, extrusion pressure and cooling conditions.
• Troubleshoot and resolve extrusion-related abnormalities such as uneven coating, insulation thickness variation, copper exposure, air bubbles and dimensional variation.
• Manage cable cutting, stripping and crimping operations to ensure dimensional accuracy and compliance with customer specifications.
• Ensure proper crimping quality by monitoring crimp height, crimp width, terminal positioning and pull-out strength.
• Identify and eliminate recurring production issues through systematic root cause analysis and corrective actions.
• Monitor production KPIs such as OEE, productivity, rejection, machine downtime, material wastage and on-time delivery.
• Ensure effective utilization of manpower, machinery and raw materials to achieve production targets within the approved cost.
• Lead and manage a team of 10 operators / technicians, ensuring effective manpower allocation, skill development and performance management.
• Coordinate with Maintenance to ensure preventive maintenance, timely breakdown resolution and maximum machine availability.
• Coordinate with Quality, Planning, Stores and other cross-functional departments to ensure smooth production flow and customer delivery requirements.
• Support implementation of engineering changes, new product trials, process validation and model change activities.
• Implement Lean Manufacturing, 5S, Kaizen and continuous improvement initiatives to improve productivity and reduce operational losses.
• Ensure adherence to SOPs, work instructions, process standards and safety requirements.
• Monitor and maintain production records, downtime reports, rejection reports and daily shift performance.
• Conduct shift reviews and communicate production performance, quality concerns and improvement actions to the reporting manager.

Key Skills Required

• 48 years of relevant experience in cable manufacturing, PVC extrusion, wire harness manufacturing or cable assembly operations.
• Strong hands-on experience in PVC insulation extrusion over copper conductors.
• Practical knowledge of multi-core flat cable manufacturing, preferably 6, 8, 10, 12, 24 and 64-core configurations.
• Strong understanding of extrusion machine operation, process parameter setting and troubleshooting.
• Hands-on experience in cable cutting, stripping, terminal crimping and assembly processes.
• Knowledge of crimping tools, applicators, crimp height measurement and pull-out strength validation.
• Ability to identify and resolve extrusion, cutting and crimping-related production abnormalities independently.
• Ability to read and interpret engineering drawings, cable specifications and customer requirements.
• Knowledge of electrical continuity, insulation resistance and short-circuit testing.
• Strong analytical, numerical and problem-solving abilities with knowledge of 5 Why and Fishbone analysis.
• Proven ability to lead, motivate and develop a team of approximately 20 operators / technicians.
• Good knowledge of production planning, manpower utilization, material control and manufacturing KPIs.
• Ability to drive productivity improvements, cost reduction, quality improvement and waste elimination.
• Effective communication and coordination skills with cross-functional teams.
• Adaptable to changing production requirements with a strong sense of ownership and accountability.

Software/Tools/System Exposure

• Strong exposure to ERP Systems like SAP, Oracle
• Exposure to HR systems and MES
• Cable production technical knowledge (Cutting,Crimping,Extrusion & MIS)