- 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
- Good 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.
- Valuable 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.