Manager EPS Plant

EPS Production | Process | Quality | Productivity | EPP Exposure

DepartmentManufacturing / OperationsFunctionEPS / Foam ManufacturingLocationBelagavi, KarnatakaReporting ToPlant Head / Head OperationsExperience712 years in EPS / EPP / foam / plastic processing / automotive manufacturingEducationDiploma / B.E. / B.Tech Mechanical, Production, Polymer, Plastics or related discipline

Role Purpose The Manager – EPS Plant will own the overall EPS manufacturing operation, including production, process stability, quality, productivity, manpower, machine utilisation, material efficiency and continuous improvement. The role will lead the EPS shop floor and coordinate with Quality, Maintenance, Tool Room, NPD, Planning and Stores to ensure reliable supply of helmet EPS liners.

The ideal candidate must have solid hands-on EPS processing and moulding experience, with practical exposure to EPP processing. EPP experience will help support future development and scale-up of advanced foam products.

1. Overall EPS Plant Operations

- Own daily EPS plant operations and achieve production, quality, cost and delivery targets.
- Plan production, machine loading, manpower deployment and shift operations.
- Ensure availability and utilisation of machines, moulds, raw materials and manpower.
- Identify bottlenecks and maintain uninterrupted production.
- Drive shop-floor discipline, safety, 5S and standard work.

1. EPS Process Management

- Own the EPS process from raw material preparation/pre-expansion through moulding, cooling, demoulding and finishing.
- Establish and maintain process parameters for EPS grades, densities, moulds and products.
- Control density, steam pressure/temperature, cycle time, cooling time, material loading and mould filling.
- Ensure process consistency across machines, shifts and operators.
- Maintain SOPs, work instructions and process parameter sheets.
- Lead troubleshooting and permanent corrective actions.

1. EPP Experience & Future Capability





- Use practical EPP processing and moulding knowledge to support EPP trials and development.
- Evaluate EPP material behaviour, moulding parameters, cycle times and process requirements.
- Work with NPD, Tool Room and suppliers during EPP mould trials and validation.
- Support future expansion into EPP and other engineered foam applications.
- Build internal EPP process capability through training and standardisation.

1. Quality & Rejection Management

- Ensure EPS liners meet dimensional, density, fusion, strength and appearance requirements.
- Control short filling, cracks, weld lines, density variation, deformation and poor fusion.
- Own rejection and rework reduction.
- Lead RCA using 5 Why, Fishbone and other problem-solving tools.
- Implement CAPA and sustain corrective actions.

1. Productivity, Cost & OEE

- Improve machine OEE, cycle time, output per machine and manpower productivity.
- Reduce material wastage, scrap and process losses.
- Conduct capacity studies and remove production bottlenecks.
- Drive Lean, Kaizen and continuous improvement projects.
- Deliver cost savings without compromising quality.

1. Machine, Mould & Maintenance Coordination

- Coordinate with Maintenance to improve machine reliability and reduce breakdowns.
- Ensure preventive maintenance is followed.
- Work with Tool Room on mould condition, changeovers and recurring issues.
- Support installation and stabilisation of new EPS/EPP machines and moulds.

1. NPD & Industrialisation

- Support development of new helmet EPS liners and other foam products.
- Lead production trials and establish repeatable mass-production parameters.
- Validate cycle time, density, dimensions, material consumption and production feasibility.




- Support new mould trials and production ramp-up.

1. Team Management

- Lead operators, technicians and engineers.
- Train the team on process parameters, machine operation, quality and problem solving.
- Build ownership, discipline, safety and continuous-improvement culture.
- Identify skill gaps and implement cross-training.

1. MIS & Reporting

- Track production vs plan, OEE, cycle time, rejection, scrap, downtime, manpower productivity and material utilisation.
- Present major losses and corrective-action plans to the Plant Head / Operations Head.
- Maintain required production and process records.

Key Performance Indicators (KPIs) KPIManagement FocusProduction achievementPlanned output and deliveryOEEContinuous improvement in availability, performance and qualityRejection & scrapContinuous reductionCycle timeOptimisation without quality lossMaterial utilisationImproved yield and reduced wastageProcess stabilityRepeatable parameters across machines and shiftsDowntimeReduction in breakdown/process lossesManpower productivityImproved output per operator/shiftQuality complaintsReduction/elimination of process-related complaintsNew product industrialisationSuccessful trials and timely ramp-upEPP capabilityEffective support for EPP trials and future production

Candidate Profile

- 7–12 years of relevant manufacturing experience, with substantial hands-on EPS moulding/processing experience.
- Prior experience managing an EPS plant, department or production line preferred.
- Practical EPP processing and moulding exposure preferred.
- Helmet EPS, automotive, polymer, foam or high-volume manufacturing experience preferred.
- Strong understanding of EPS density control, pre-expansion, steam moulding, cooling, demoulding and cycle optimisation.
- Experience in production planning, manpower management, OEE, Lean, 5S, RCA and CAPA.
- Good machine, mould and process troubleshooting capability.
- Good Excel/MIS skills; ERP/MES experience is an advantage.

📌 Manager EPS Plant (Belagavi)
🏢 Vega Auto Accessories
📍 Belagavi