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.
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 protected handling of heavy tubes and rotating equipment
Maintain protected working workplace around the machine
Key Performance Indicators (KPIs)
Production output (tons/shift)
Yield (%) and material recovery
Rejection rate (%)
Tool life (dies/mandrels)
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