BOPP Mainline Supervisor

Job Description:

ob Description – BOPP Mainline Supervisor

Position: BOPP Mainline Supervisor
Department: Production / Manufacturing
Reporting To: Production Manager / Plant Head

Job Purpose

The BOPP Mainline Supervisor is responsible for supervising and coordinating the day-to-day operation of the Biaxially Oriented Polypropylene (BOPP) film production line, ensuring safe, efficient, and continuous production in accordance with prescribed quality standards, production targets, and operating procedures.

Key Responsibilities

• Supervise the operation of the complete BOPP mainline, including extrusion, casting, machine direction orientation (MDO), transverse direction orientation (TDO), and related sections.
• Ensure continuous and stable operation of the production line with minimum downtime and production losses.
• Monitor and control critical process parameters such as temperature, pressure, line speed, stretching ratios, cooling conditions, thickness, and other relevant operating parameters.
• Ensure production is carried out according to the approved production plan, product specifications, and quality requirements.
• Coordinate with the Quality, Maintenance, Electrical, Utilities, and Process/Technical teams to resolve operational issues promptly.
• Monitor film quality and take immediate corrective action in case of defects such as thickness variation, gels, haze, wrinkles, blocking, scratches, edge defects, poor winding, and other abnormalities.
• Ensure proper changeover of products, grades, thicknesses, and specifications with minimum material wastage and downtime.
• Supervise operators and technicians working on the mainline and allocate duties according to operational requirements.
• Ensure adherence to Standard Operating Procedures (SOPs), Work Instructions, and approved process parameters.
• Maintain proper production records, shift reports, downtime reports, consumption records, and other relevant documentation.
• Identify the causes of production losses, process instability, and equipment-related problems and coordinate corrective actions.
• Ensure optimum utilization of raw materials, additives, energy, manpower, and other production resources.
• Monitor scrap and wastage and implement measures to minimize production losses.
• Coordinate with the Maintenance Department for preventive and breakdown maintenance and ensure safe equipment handover and takeover.
• Ensure proper housekeeping and compliance with 5S, safety, and environmental requirements within the production area.
• Ensure that all safety procedures, permit-to-work requirements, PPE requirements, and emergency procedures are strictly followed.
• Train, guide, and develop operators and junior production personnel on machine operation, process control, quality requirements, and safety practices.
• Participate in root-cause analysis and corrective/preventive action (CAPA) activities for recurring production and quality problems.
• Report major abnormalities, breakdowns, quality deviations, and safety incidents to the Production Manager/Plant Head immediately.
• Ensure effective communication and proper shift handover between incoming and outgoing teams.

Key Performance Indicators (KPIs)

• Production output and achievement against production plan
• Line efficiency and OEE
• Reduction in downtime
• Reduction in process waste and scrap
• Product quality and rejection rate
• Raw-material and energy consumption
• Changeover time
• Compliance with SOPs and process parameters
• Safety performance and housekeeping
• Effective manpower utilization