- Manage and supervise the complete phosphating process and plant operations.
- Ensure proper preparation, operation and maintenance of phosphating baths and chemical treatment tanks.
- Monitor and control critical process parameters such as:
- Chemical concentration
- pH value
- Temperature
- Treatment time
- Bath condition
- Surface quality
Ensure proper pre-treatment, degreasing, pickling, rinsing and phosphating processes. Maintain proper chemical dosing and ensure timely bath analysis and replenishment. Coordinate with the Quality Department for process inspection and quality control. Maintain process records, chemical consumption records and daily production reports. Identify process deviations and take corrective action to maintain consistent product quality. Ensure proper handling, storage and usage of chemicals as per safety procedures. Ensure compliance with safety requirements, PPE usage and environmental requirements. Coordinate with Production, Quality, Maintenance and Stores Departments for smooth operations.
Supervise and guide operators and contract manpower working in the phosphating plant. Monitor chemical consumption and minimize process wastage. Ensure proper housekeeping and 5S practices in the plant area. Support continuous improvement initiatives for process efficiency, quality improvement and cost reduction.
Additional Advantage
Knowledge of pickling and surface treatment processes in tube manufacturing companies, particularly:
- Acid pickling
- Degreasing
- Rinsing
- Phosphating
- Chemical bath control
- Surface preparation of tubes
- Process parameter monitoring
will be considered an added advantage.
Required Skills
- Valuable knowledge of chemical process control.
- Knowledge of phosphating and pickling chemicals and processes.
- Ability to monitor and control chemical bath parameters.
- Understanding of quality requirements and surface treatment standards.
- Good analytical and problem-solving skills.
- Knowledge of industrial safety and chemical handling procedures.
- Ability to lead and supervise plant operators and manpower.
- Good coordination and communication skills.
Key Performance Indicators (KPIs)
- Phosphating process quality and consistency.
- Reduction in chemical consumption and wastage.
- Compliance with process parameters.
- Reduction in rejection and rework due to surface treatment defects.
- Timely completion of production schedules.
- Compliance with safety and environmental requirements.
- Proper maintenance of process records and documentation.
- Effective manpower utilization and plant housekeeping.