The Pilger Operator is responsible for operating cold pilger mills to reduce tube diameter and wall thickness while maintaining strict dimensional tolerances, surface quality, and productivity targets. The role is critical to achieving consistent tube quality for HVAC, refrigeration, and industrial applications.
2. Key ResponsibilitiesMachine Operation
- Operate pilger mill (feed, rolling, and extraction cycles) as per defined pass schedule
- Set up tooling (dies, mandrels, saddles) as per product specification
- Ensure correct alignment and positioning before starting production
Process Control
- Follow approved pilger pass profile and reduction schedule
- Monitor:
- Diameter reduction
- Wall thickness consistency
- Surface finish
- Adjust feed rate, stroke rate, and lubrication as required
Quality Assurance
- Check tube dimensions using vernier, micrometer, and gauges
- Ensure compliance with internal specs and standards like ASTM
- Identify and prevent defects:
- Eccentricity
- Surface cracks
- Tool marks
- Thickness variation
Tooling Management
- Inspect dies and mandrels before and after use
- Report wear, damage, or mismatch immediately
- Ensure proper lubrication and cooling of tools
Material Handling
- Load mother tubes safely onto the machine
- Ensure correct tube ID/OD and heat number before processing
- Segregate finished, rejected, and rework material
Maintenance Support
- Perform routine checks (oil levels, lubrication, cooling system)
- Support maintenance team during breakdowns or changeovers
- Maintain machine cleanliness and 5S standards
Safety & Compliance
- Follow all safety protocols (PPE, machine guards, lockout/tagout)
- Ensure safe handling of heavy tubes and rotating equipment
- Maintain protected working environment around the machine
3. Key Performance Indicators (KPIs)
- Production output (tons/shift)
- Yield (%) and material recovery
- Rejection rate (%)
- Tool life (dies/mandrels)
- Ma