Extrusion Manager at Dangote

Job Purpose

• The Extrusion Manager is responsible for leading and managing the extrusion department to ensure the efficient, safe, and high-quality production of PP tapes used for DPL sacks.
• The role includes managing manpower, ensuring product quality, reducing waste, maintaining machines, and coordinating with weaving, lamination, and quality departments to ensure smooth production flow.

Duties & Reponsibilities
Production & Process Management:

• Plan, schedule, and monitor daily extrusion production activities to meet output targets.
• Oversee the operation of tape extrusion lines, including Lamination/Coating lines if applicable.
• Optimize extrusion parameters (temperature, L/D ratio, die gap, quench, stretching ratios, winders) to ensure consistent tape quality.
• Monitor raw material consumption (PP, HDPE, additives, masterbatch) and ensure optimal usage and mixing ratios.
• Ensure smooth flow of materials from compounding to winding and onward to weaving.

Quality Control:

• Maintain quality standards for tensile strength, elongation, denier consistency, shrinkage, and tape uniformity.
• Coordinate with the QA team to address quality deviations and implement corrective actions.
• Conduct root-cause analysis for defects such as tape breakage, inconsistent denier, melt flow issues, and color variations.

Manpower & Team Leadership:

• Supervise extrusion operators, helpers, and shift-in-charge staff.
• Conduct training on machine operation, safety, and productivity improvement.
• Ensure proper shift handovers and performance management of team members.

Machine Maintenance & Upkeep:

• Coordinate with the maintenance team for preventive and breakdown maintenance of extrusion lines.
• Ensure proper condition of dies, heaters, godets, chill rollers, T-Die, stretching units, AC motors/inverters, and winding systems.
• Maintain spare parts inventory (heaters, thermocouples, filters, blades, bearings, etc.).

Productivity & Cost Control:

• Drive initiatives to reduce wastage, power consumption, and downtime.
• Track KPIs such as output kg/hr, waste %, tape breakage rate, and energy usage.
• Implement lean manufacturing practices and continuous improvement initiatives.

Documentation & Compliance:

• Maintain production logs, shift reports, material tracking sheets, and downtime analyses.
• Ensure compliance with safety, environmental, and statutory guidelines.
• Support ISO, GMP, or other audits as applicable.

Job Requirements

• Education: Bachelor's degree in Polymer Science, Chemical Engineering, Mechanical Engineering, or a related technical field.
• Experience: 5-12 years of progressive experience in PP woven sacks industry, with at least 2 - 5 years in an extrusion supervisory or managerial role. Added Advantage: Hands-on experience with high-speed extrusion/tape lines
• Technical Knowledge: Proven expertise in the operation, maintenance, and process optimization of modern PP Tape Extrusion lines.

Competencies:

• In-depth knowledge of PP extrusion process, polymers, additives, and tape production.
• Strong understanding of extrusion machinery (Lohia, Starlinger, Yongming, etc.).
• Problem-solving and troubleshooting skills in process and machine issues.
• Ability to lead and motivate a large team across multiple shifts.
• Strong analytical, planning, and communication skills.
• Familiarity with lean, 5S, and Kaizen practices is a plus.