Ideal Standard International Egypt
Factory Manager - Masterbatch
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Job Description
- Manage daily factory operations to achieve production plans safely, efficiently, and on schedule.
- Convert monthly sales forecasts and confirmed orders into weekly and daily production plans.
- Monitor production output by line, shift, product, grade, and batch.
- Ensure compliance with approved formulations, processing parameters, and operating procedures.
- Coordinate production priorities with sales, planning, procurement, warehouse, quality, and logistics teams.
- Ensure accurate production reporting and timely entry of manufacturing data into the company’s ERP system.
- Investigate production delays, capacity limitations, and operational bottlenecks and implement corrective actions.
- Supervise single-screw and twin-screw extrusion lines, depending on the factory’s equipment.
- Control feeding, mixing, compounding, extrusion, cooling, pelletizing, sieving, packing, and finished-product handling.
- Monitor critical processing parameters, including:Extruder temperature profileScrew speed and torqueFeeding and dosing ratesMelt pressure and temperatureVacuum and venting conditionsCooling-water performancePelletizer speed and cutting qualityLine output and energy consumption
- Extruder temperature profile
- Screw speed and torque
- Feeding and dosing rates
- Melt pressure and temperature
- Vacuum and venting conditions
- Cooling-water performance
- Pelletizer speed and cutting quality
- Line output and energy consumption
- Ensure correct machine setup and process conditions during grade changes and production start-ups.
- Reduce start-up losses, color-change waste, contamination, black specks, inconsistent pellets, and unplanned stoppages.
- Support troubleshooting of dispersion, agglomeration, moisture, feeding, pressure, pelletizing, and processing problems.
- Supervise the production of:Calcium carbonate filler masterbatchPE- and PP-based filler masterbatchColor masterbatchWhite and black masterbatch, where applicablePVC compoundsCalcium carbonate-based plastic compoundsRecycled plastic compounds, where applicable
- Calcium carbonate filler masterbatch
- PE- and PP-based filler masterbatch
- Color masterbatch
- White and black masterbatch, where applicable
- PVC compounds
- Calcium carbonate-based plastic compounds
- Recycled plastic compounds, where applicable
- Ensure accurate weighing and dosing of calcium carbonate, polymers, pigments, waxes, processing aids, coupling agents, dispersing agents, and other additives.
- Control formulation changes and ensure that unauthorized substitutions are not made.
- Work with technical and quality teams to improve dispersion, processability, loading level, pellet quality, and product consistency.
- Support industrial trials, product development, scale-up, and customer-specific production requirements.
- Coordinate closely with Quality Control and Technical teams to ensure compliance with approved product specifications.
- Ensure proper sampling, batch identification, traceability, testing, release, and retention-sample procedures.
- Review quality results such as:Melt Flow IndexCalcium carbonate or ash contentMoistureDensity and bulk densityColor strength and color differencePigment and filler dispersionPellet size and uniformityBlack specks and contaminationMechanical and processing performance, where applicable
- Melt Flow Index
- Calcium carbonate or ash content
- Moisture
- Density and bulk density
- Color strength and color difference
- Pigment and filler dispersion
- Pellet size and uniformity
- Black specks and contamination
- Mechanical and processing performance, where applicable
- Investigate rejected batches, customer complaints, production deviations, and repeated quality problems.
- Implement corrective and preventive actions and verify their effectiveness.
- Ensure nonconforming materials are clearly identified, isolated, and controlled.
- Coordinate preventive, predictive, and corrective maintenance with the maintenance team.
- Monitor the condition of extruders, gearboxes, screws, barrels, feeders, mixers, pelletizers, cooling systems, compressors, dust collectors, and packing machines.
- Analyze equipment failures and repeated downtime using root-cause analysis.
- Plan maintenance activities to minimize disruption to customer orders.
- Ensure critical spare parts are identified and available.
- Monitor equipment condition and recommend repairs, upgrades, or capital investments when justified.
- Monitor production cost per kilogram or metric ton.
- Control polymer, calcium carbonate, pigment, additive, packaging, energy, and labor consumption.
- Compare actual material consumption against approved bills of materials and standard consumption.
- Reduce raw-material losses, off-specification batches, reprocessing, packaging waste, and production scrap.
- Improve line productivity, production yield, and energy efficiency.
- Identify and implement cost-saving initiatives without compromising product quality or safety.
- Prepare regular variance reports covering output, consumption, waste, downtime, and production cost.
- Coordinate raw-material requirements with procurement and warehouse teams.
- Maintain appropriate stock levels for critical polymers, minerals, additives, pigments, and packaging materials.
- Ensure proper storage and handling of calcium carbonate, polymers, pigments, additives, and finished products.
- Apply FIFO or FEFO principles where appropriate.
- Prevent material contamination, incorrect identification, moisture exposure, and unauthorized use.
- Participate in stock counts and investigate production-related inventory variances.
- Lead production supervisors, shift leaders, operators, helpers, and other factory personnel.
- Establish clear responsibilities, shift structures, and performance expectations.
- Assess workforce requirements based on production plans and equipment capacity.
- Train employees on operating procedures, quality requirements, safety practices, and good housekeeping.
- Evaluate employee performance and recommend training, development, recognition, or corrective action.
- Build a culture of accountability, teamwork, discipline, problem-solving, and continuous improvement.
- Ensure effective communication between shifts and departments.
- Enforce company health, safety, environmental, and housekeeping requirements.
- Ensure safe handling of powders, pigments, additives, polymers, hot surfaces, rotating machinery, and electrical equipment.
- Ensure the correct use of personal protective equipment.
- Control dust emissions and ensure ventilation and dust-collection systems operate effectively.
- Participate in risk assessments, incident investigations, safety inspections, and emergency drills.
- Ensure machine guards, emergency stops, fire-protection systems, and material-handling equipment remain operational.
- Maintain factory areas according to 5S and good manufacturing practices.
- Apply continuous-improvement tools to enhance output, quality, safety, and cost performance.
- Use root-cause analysis, Pareto analysis, 5 Why, OEE, 5S, and other appropriate manufacturing tools.
- Standardize successful processing conditions and best operating practices.
- Prepare daily, weekly, and monthly factory performance reports.
- Present production results, challenges, corrective actions, and improvement plans to senior management.
- Support capacity planning, equipment selection, production-line expansion, and factory-development projects.
Requirements & Qualifications
- Bachelor’s degree in Chemical Engineering, Production Engineering, Mechanical Engineering, Polymer Engineering, Materials Engineering, Industrial Engineering, or a related discipline.
- Technical postgraduate studies, an MBA, or professional manufacturing certification would be an advantage.
- Good command of written and spoken English.
- Good computer skills, including Microsoft Excel and ERP or manufacturing-management systems.
- Minimum8–20 years of relevant manufacturing experience, preferably in plastics compounding, masterbatch, or extrusion.
- Minimum3–5 years in a production-management, operations-management, or factory-management position.
- Proven experience managing production teams and shift-based manufacturing operations.
- Practical experience with filler masterbatch, color masterbatch, calcium carbonate compounds, PE/PP compounds, PVC compounds, or recycled plastic compounds is highly preferred.
- Experience in an export-oriented or quality-certified industrial company is an advantage.
- Plastic extrusion and compounding processes
- Single-screw and twin-screw extruders
- Gravimetric and volumetric dosing systems
- High-speed mixers and material-blending systems
- Strand and underwater pelletizing systems, where applicable
- PE, PP, PVC, recycled polymers, and related carrier resins
- Calcium carbonate, coated calcium carbonate, pigments, waxes, dispersants, and processing additives
- Masterbatch formulations and bills of materials
- Pigment and filler dispersion
- Color matching and color-difference control
- Extrusion troubleshooting and process optimization
- Production planning and capacity utilization
- Preventive maintenance coordination
- Quality-control procedures and batch traceability
- Material-consumption analysis and cost control
- Lean manufacturing, 5S, OEE, and root-cause analysis
- ERP/MRP systems; experience with Odoo is an advantage
- Strong leadership and team-management ability
- Practical, hands-on manufacturing approach
- Effective planning and prioritization
- Strong analytical and problem-solving skills
- Ability to make timely operational decisions
- Cost awareness and commercial understanding
- Effective communication across technical and nontechnical departments
- Ability to manage pressure, changing priorities, and urgent customer orders
- Strong discipline in documentation, reporting, and follow-up
- Ability to coach, train, and develop production personnel
- Filler masterbatch
- Color masterbatch
- Calcium carbonate compounds
- Plastic extrusion and compounding
- PE or PP masterbatch
- PVC compounds
- Cable compounds
- Injection- or blow-molding compounds
- Plastic recycling and recycled compounds
- Industrial mineral processing
- Polymer additives or pigment manufacturing
- Responsible, disciplined, and results-oriented
- Visible and engaged on the factory floor
- Detail-focused without losing sight of overall business objectives
- Ethical and consistent in applying company procedures
- Calm and decisive when handling production problems
- Proactive in identifying operational risks
- Committed to safety, product quality, and customer satisfaction
- Capable of building a stable, accountable production team
EGjobank Analysis
Quick Role Summary
Opportunity as "Factory Manager - Masterbatch" at شركة رائدة located in بني سويف on a Full-Time basis, suited for Fresh Graduate candidates, within Marketing & Sales. Key details from listing: • Manage daily factory operations to achieve production plans safely, efficiently, and on schedule. • Convert monthly sales forecasts and confirmed orders into…
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