Position Title: Production Manager - Enamelling Department

Department: Production

Reports To: Vice President - Operations / Plant Head

Location: Narsanda, Nadiad, Dist. Kheda, Gujarat

Job Purpose

To lead and manage the Enamelling Department for manufacturing high-quality enamelled copper & aluminium wires, strips, and continuously transposed conductors (CTC) as per customer specifications and international standards, ensuring productivity, quality, safety, and cost-effectiveness while supporting new product development and customer requirements.

Key Responsibilities

Production & Operations

- Plan, organize, and oversee enamelling operations for wires, strips, and CTC to meet production schedules.

- Monitor line performance, output, and machine utilization (OEE).

- Ensure optimum use of raw materials (copper/aluminium, varnishes, dies, lubricants).

- Control wastage, rejections, and energy consumption.

- Coordinate with Planning & Dispatch to achieve on-time delivery.

Quality & Process Control

- Ensure products comply with IEC, IS, NEMA, ASTM, and customer-specific standards.

- Monitor film build, adhesion, flexibility, dielectric properties, thermal class, and other critical parameters.

- Collaborate with QA/QC to resolve in-process and customer quality issues.

- Implement corrective and preventive actions to eliminate defects and complaints.

CTC & Strip Enamelling Focus

- Oversee enamelling process for strips and continuously transposed conductors, ensuring consistency in insulation quality.

- Optimize enamelling for large cross-section conductors used in transformers and electrical machines.

- Ensure uniform enamel coating thickness and insulation properties for heavy-duty applications.

Technology & Process Improvement

- Drive continuous improvements in enamelling technology, productivity, and cost reduction.

- Support for new enamel types, higher temperature grades, dual coatings, and customized products.

- Evaluate and implement best practices in enamelling for high-performance wires and CTC.

Team Management

- Lead and motivate supervisors, operators, and technical staff.

- Allocate manpower effectively across different enamelling lines.

- Conduct training programs on process control, quality, and safety.

Maintenance & Coordination

- Coordinate with Maintenance to minimize breakdowns and downtime of enamelling lines.

- Plan preventive maintenance and ensure machine health.

- Liaise with Purchase/Stores for timely availability of consumables and raw materials.

Safety & Compliance

- Ensure compliance with EHS standards, particularly in handling varnishes, solvents, and chemicals.

- Enforce safe operating practices to achieve zero accidents.

- Adhere to statutory and environmental regulations.

Reporting & Documentation

- Prepare daily, weekly, and monthly reports on production, rejections, efficiency, and downtime.

- Support internal, customer, and certification audits (ISO, IATF, UL, RoHS, etc.).

- Maintain process records and traceability documentation.

Key Performance Indicators (KPIs)

- Achievement of production targets (output in MT/KM).

- Rejection and rework percentage reduction.

- Machine utilization (OEE) and downtime reduction.

- Cost savings in enamel, energy, and consumables.

- On-time delivery adherence.

- Customer complaint reduction and quality improvements.

- Safety compliance and zero accidents.

Candidate Profile

Education:

- B.E. / B. Tech in Electrical, Mechanical, Production, Industrial Engineering or related engineering field.

Experience:

- 12-15 years in wire & conductor manufacturing industry.

- Minimum 5 years of managerial experience in enamelling of copper/aluminium wires, strips, and CTC.

- Hands-on knowledge of enamelling lines (horizontal, vertical, and strip lines).

- Experience with high voltage/motor wire, strip, and CTC applications for transformer industry and related field.

Skills & Competencies:

- Strong technical expertise in enamelling process control and troubleshooting.

- Familiarity with varnish chemistry, insulation systems, and curing cycles.

- Analytical and problem-solving abilities.

- Excellent leadership, team management, and communication skills.

- ERP/MIS reporting proficiency.