Head of Department; HOD Extrusion Job Durban area,South Africa,Manufacturing / Production

Position: Head of Department (HOD) – Extrusion

To lead, manage, and optimize all extrusion operations within the flexible packaging manufacturing environment, ensuring the safe, efficient, and cost-effective production of high-quality films that meet customer specifications. The HOD Extrusion is responsible for delivering production targets, driving continuous improvement, managing people and resources, and maintaining world-class manufacturing standards.

Key Responsibilities Production Management

Lead and oversee all blown film and/or cast film extrusion operations
Ensure production schedules are executed in line with customer demand and planning requirements
Monitor production output, machine efficiency, and shift performance
Optimize machine utilization and capacity planning
Ensure adherence to production standards, recipes, and operating procedures
Coordinate with planning, printing, laminating, slitting, and dispatch departments to achieve operational objectives

Process Control and Optimization

Monitor and control extrusion process parameters including:
- Melt temperature
- Extrusion pressure
- Die settings
- Gauge control
- Line speed
- Cooling systems
- Resin blends
Ensure film thickness consistency and product conformance
Lead process improvement initiatives to improve productivity and quality
Conduct root cause analysis for process deviations and performance losses
Drive reduction of waste, edge trim, start-up scrap, and downtime

Quality Management

Ensure all extruded products meet customer specifications and quality requirements
Monitor key quality attributes including:
- Film thickness
- Tensile strength
- Haze and clarity
- Coefficient of friction (COF)
- Printability requirements
Support customer approvals and quality audits.
Implement corrective and preventive actions for quality concerns
Work closely with the Quality Department to ensure compliance with ISO, BRCGS, and customer standards

Leadership and People Management

Lead, coach, and develop extrusion supervisors and operators
Establish a high-performance culture focused on safety, quality, and productivity
Conduct performance reviews and employee development plans
Identify training needs and competency gaps
Manage employee relations, attendance, discipline, and grievance matters in accordance with company policies
Promote employee engagement and teamwork

Safety, Health and Environmental Compliance

Ensure full compliance with Occupational Health and Safety regulations
Promote a zero-harm safety culture
Conduct regular risk assessments and workplace inspections
Ensure safe handling and storage of raw materials and chemicals
Investigate accidents, incidents, and near-misses
Implement corrective actions to prevent recurrence
Ensure compliance with environmental standards and waste management procedures

Maintenance and Asset Management

Partner with the Maintenance Department to maximize equipment reliability
Support preventive and predictive maintenance programs
Monitor machine performance and address recurring breakdowns
Participate in equipment upgrades and capital expenditure projects
Improve machine uptime and Overall Equipment Effectiveness (OEE)

Cost and Inventory Management

Manage departmental budgets and operational costs
Monitor raw material consumption including resins, additives, master batches, and recycled materials
Reduce waste and improve material yield
Control overtime and labour costs
Ensure accurate inventory management and reporting

Continuous Improvement

Lead Lean Manufacturing, TPM, Six Sigma, and operational excellence initiatives
Identify opportunities for automation and process enhancements
Implement best practices to improve productivity and quality
Develop and track departmental improvement projects
Benchmark performance against industry standards

Customer and Audit Support

Support customer visits, technical reviews, and…