Job Title: Specialist - Flat or round Cable manufacturing - Extrusion machine operation

Job Summary:

Responsible for end-to-end Flat cable & Round cable manufacturing and assembly operations, ensuring Safety, Quality, Productivity, Cost and Delivery targets through effective management of PVC extrusion, cable cutting, stripping and crimping processes. The role involves troubleshooting production-related issues, optimizing manufacturing processes and managing a team of 20 members to achieve operational excellence.

Key Result Areas (Accountability & Responsibility of the role)

- Lead by example, ensuring a safe and efficient working environment across all flat cable manufacturing and assembly operations.
- Independently manage and monitor PVC extrusion machine operations, ensuring consistent coating of copper conductors with PVC insulation.
- Ensure achievement of daily production targets for 6, 8, 10, 12, 24 and 64-core flat cable configurations.
- Establish, monitor and control critical extrusion parameters, including temperature zones, screw speed, line speed, extrusion pressure and cooling conditions.
- Troubleshoot and resolve extrusion-related abnormalities such as uneven coating, insulation thickness variation, copper exposure, air bubbles and dimensional variation.
- Manage cable cutting, stripping and crimping operations to ensure dimensional accuracy and compliance with customer specifications.
- Ensure proper crimping quality by monitoring crimp height, crimp width, terminal positioning and pull-out strength.
- Identify and eliminate recurring production issues through systematic root cause analysis and corrective actions.
- Monitor production KPIs such as OEE, productivity, rejection,



machine downtime, material wastage and on-time delivery.
- Ensure effective utilization of manpower, machinery and raw materials to achieve production targets within the approved cost.
- Lead and manage a team of 10 operators / technicians, ensuring effective manpower allocation, skill development and performance management.
- Coordinate with Maintenance to ensure preventive maintenance, timely breakdown resolution and maximum machine availability.
- Coordinate with Quality, Planning, Stores and other cross-functional departments to ensure smooth production flow and customer delivery requirements.
- Support implementation of engineering changes, new product trials, process validation and model change activities.
- Implement Lean Manufacturing, 5S, Kaizen and continuous improvement initiatives to improve productivity and reduce operational losses.
- Ensure adherence to SOPs, work instructions, process standards and safety requirements.
- Monitor and maintain production records, downtime reports, rejection reports and daily shift performance.
- Conduct shift reviews and communicate production performance, quality concerns and improvement actions to the reporting manager.

Key Skills Required

- 48 years of relevant experience in cable manufacturing, PVC extrusion,



wire harness manufacturing or cable assembly operations.
- Solid hands-on experience in PVC insulation extrusion over copper conductors.
- Practical knowledge of multi-core flat cable manufacturing, preferably 6, 8, 10, 12, 24 and 64-core configurations.
- Strong understanding of extrusion machine operation, process parameter setting and troubleshooting.
- Hands-on experience in cable cutting, stripping, terminal crimping and assembly processes.
- Knowledge of crimping tools, applicators, crimp height measurement and pull-out strength validation.
- Ability to identify and resolve extrusion, cutting and crimping-related production abnormalities independently.
- Ability to read and interpret engineering drawings, cable specifications and customer requirements.
- Knowledge of electrical continuity, insulation resistance and short-circuit testing.
- Strong analytical, numerical and problem-solving abilities with knowledge of 5 Why and Fishbone analysis.
- Proven ability to lead, motivate and develop a team of approximately 20 operators / technicians.
- Good knowledge of production planning, manpower utilization, material control and manufacturing KPIs.
- Ability to drive productivity improvements, cost reduction, quality improvement and waste elimination.
- Effective communication and coordination skills with cross-functional teams.
- Adaptable to changing production requirements with a strong sense of ownership and accountability.

Software/Tools/System Exposure

- Strong exposure to ERP Systems like SAP, Oracle
- Exposure to HR systems and MES
- Cable production technical knowledge (Cutting,Crimping,Extrusion & MIS)

📌 Specialist - Flat or Round Cable Manufacturing (Krishnagiri)
🏢 Ola Electric
📍 Krishnagiri