About the role
Job Description – Assistant Manager – Double Twist Bunching
Company: Bharat Wire Ropes Ltd. (BWRL)
Location: Chalisgaon, Maharashtra
Department: Production – Bunching
Designation: Assistant Manager – Bunching
Experience: 8–12 Years
Industry: Wire Rope / Steel Wire Manufacturing
What you'll do
- Job Summary
- Bharat Wire Ropes Ltd. is looking for an experienced Assistant Manager – Bunching with strong hands-on experience in Double Twist Bunching operations.
- The candidate will be responsible for managing Double Twist Bunching Machines, production planning, machine setting, process parameters, manpower, quality, productivity, troubleshooting, and coordination with Maintenance and Quality teams.
- Candidates with hands-on experience in Double Twist Bunchers used for wire rope manufacturing will be preferred.
- Key Responsibilities
- 1.
- Double Twist Bunching Operations
- Manage day-to-day operations of Double Twist Bunching Machines.
- Set and monitor machine parameters as per product and construction requirements.
- Ensure proper bunching of wires as per defined specifications.
- Monitor lay length, tension, wire alignment, closing, pitch and bunching quality.
- Ensure smooth running of machines with minimum breakdown and downtime.
- Troubleshoot process-related issues during production.
- 2.
- Production Planning & Target Achievement
- Plan daily and monthly production based on production schedules.
- Ensure achievement of production targets while maintaining quality standards.
- Monitor machine productivity, utilization and operating efficiency.
- Coordinate with PPC, Quality, Maintenance and Stores for uninterrupted production.
- 3.
- Machine Setting & Process Control
- Handle machine setting, changeovers and adjustment of Double Twist Bunchers.
- Ensure correct tooling, dies, bobbins, guides and other machine components are used.
- Monitor and control process parameters during production.
- Identify deviations and take immediate corrective action.
- 4.
- Wire Rope / Wire Product Knowledge
- Good understanding of wire rope constructions and bunching processes.
- Knowledge of different wire sizes, grades and configurations used in wire rope manufacturing.
- Understanding of strand formation and its impact on final rope quality.
- Ensure correct construction and dimensional requirements are achieved.
- 5.
- Quality Control
- Ensure bunching output meets defined quality specifications.
- Coordinate with the Quality department for inspection and testing.
- Investigate defects such as improper lay, uneven tension, wire displacement, loose/irregular bunching and other process-related defects.
- Implement corrective and preventive actions.
- 6.
- Manpower Management
- Supervise operators, technicians and helpers working in the bunching section.
- Allocate manpower based on production requirements.
- Train operators on Double Twist Buncher operation, machine settings, quality and safety.
- Monitor operator performance and discipline.
- 7.
- Maintenance Coordination
- Coordinate with Maintenance for preventive and breakdown maintenance of Double Twist Bunching Machines.
- Identify recurring machine problems and support root-cause analysis.
- Minimize machine breakdowns and downtime.
- Ensure machines are maintained in optimum operating condition.
- 8.
- Productivity & Cost Improvement
- Improve machine productivity and reduce production losses.
- Monitor material consumption, wastage, rejection and rework.
- Identify opportunities for process optimization and cost reduction.
- Drive Kaizen, 5S, TPM and continuous improvement activities.
- 9.
- Safety
- Ensure safe operation of Double Twist Bunching Machines.
- Ensure operators follow PPE and safety procedures.
- Maintain proper housekeeping and 5S in the production area.
- Identify and report potential safety hazards.
- 10.
- Production MIS & Reporting
- Prepare daily production and machine performance reports.
- Monitor:
- Production vs. target
- Machine utilization
- Machine downtime
- Rejection/rework
- Material wastage
- Productivity
- Quality issues
- Report production performance and major issues to senior management.
What we're looking for
- Required Experience
- Mandatory:
- 8–12 years of experience in manufacturing/production.
- Strong hands-on experience in Double Twist Bunching.
- Experience operating/handling Double Twist Bunching Machines.
- Experience in wire rope / steel wire manufacturing is highly preferred.
- Experience in machine setting, troubleshooting and process control.
- Experience handling production operators and shop-floor manpower.
- Education
- Diploma / B.E. / B.Tech – Mechanical / Production / Metallurgy or related engineering discipline
- Preferred Candidate Profile
- Candidates currently working as:
- Assistant Manager – Bunching
- Bunching In-charge
- Double Twist Bunching In-charge
- Bunching Production Engineer
- Senior Bunching Engineer
- Production Engineer – Wire Rope
- Strand/Bunching Production Engineer
- Industry preference: Wire Rope Manufacturing / Steel Wire Manufacturing / Cable Manufacturing / related metal wire manufacturing.