Job Purpose

The General Helper – Extrusion is responsible for supporting the Extrusion Department with daily production activities to ensure the safe, efficient and continuous manufacture of PVC and PE pipes and related products.

The role includes assisting Extrusion Operators with material preparation and handling, product handling, packing, scrap control, machine changeovers, housekeeping and general production activities.

The General Helper must follow all production, quality, Health & Safety and housekeeping requirements and carry out instructions provided by the Extrusion Operator, Supervisor or Management.

Key Responsibilities

A. Production Support

•        Assist Extrusion Operators with the daily operation of extrusion production lines.

•        Prepare the work area before production starts.

•        Assist with machine start-up and shutdown activities as instructed.

•        Assist with product changeovers, size changes and tooling changes.

•        Ensure required tools, materials and production equipment are available.

•        Assist Operators during production to maintain continuous operation.

•        Monitor the production area and immediately report abnormalities to the Operator or Supervisor.

•        Assist with removing finished products from the production line.

•        Follow the production plan and instructions issued by the Supervisor.

B. Raw Material Handling

•        Assist with transporting raw materials to the production area.

•        Ensure the correct raw material is supplied to the correct production line.

•        Check material identification before use.

•        Assist with loading material into hoppers, mixers or feeding systems when instructed.

•        Assist with weighing raw materials where required.

•        Prevent contamination or mixing of different raw materials.

•        Return unused materials to the designated storage area.

•        Immediately report incorrect, damaged or contaminated materials.

C. Finished Product Handling

•        Remove and handle finished pipes and rolls safely.

•        Arrange finished products in designated areas.

•        Assist with counting finished products.

•        Assist with measuring and verifying product lengths where required.

•        Bundle, strap, wrap or pack products according to company requirements.

•        Ensure products are correctly identified and labelled.

•        Prevent damage to finished products during handling and storage.

•        Assist with transferring completed production to the Finished Goods area.

D. Product Quality Support

•        Carry out basic visual inspections of products during handling.

•        Look for obvious defects such as:

o    Incorrect colour o     Burns or black marks o       Surface damage o Cracks o    Deformation o       Incorrect cutting o    Poor socketing o       Contamination o    Other visible defects

•        Immediately report suspected defects to the Extrusion Operator, Supervisor or Quality Department.

•        Separate suspect or rejected products from acceptable products.

•        Do not mix rejected products with approved finished goods.

•        Follow instructions from the Quality Department regarding product segregation.

E. Scrap, Regrind & Waste Control

•        Collect production scrap and waste from the extrusion lines.

•        Separate scrap according to material type, product type or colour as instructed.

•        Ensure scrap intended for regrinding is kept free from contamination.

•        Place scrap and regrind in the correct designated containers or storage areas.

•        Assist with weighing and recording scrap where required.

•        Assist with transferring suitable scrap for regrinding or pulverising.

•        Ensure contaminated or non-reusable waste is placed in the appropriate waste area.

•        Support the department in reducing unnecessary production waste.

F. Machine Changeovers & Tooling

Under the supervision of an authorised Operator, Technician or Supervisor:

•        Assist with die and tooling changes.

•        Assist with removing and installing sizing sleeves and related tooling.

•        Assist with cleaning dies, tooling and production equipment.

•        Assist with pipe size and product changeovers.

•        Prepare tools and equipment required for changeovers.

•        Clean and correctly store tooling after use.

•        Report damaged tooling or equipment immediately.

The General Helper must not make unauthorised changes to machine temperatures, speeds, pressures, vacuum settings or other production parameters.

G. Packing & Identification

•        Pack finished products according to approved packing requirements.

•        Ensure bundles contain the correct quantities.

•        Assist with attaching product labels and identification.

•        Ensure different products, sizes, pressure classes or batches are not mixed.

•        Keep completed products organised and ready for transfer to Finished Goods.

•        Report damaged packaging or incorrectly identified products.

H. Housekeeping & 5S

•        Maintain a clean and organised extrusion production area.

•        Clean around machines and production lines.

•        Remove unnecessary scrap, material, packaging and waste.

•        Keep walkways, emergency exits and access points clear.

•        Return tools and equipment to designated storage locations after use.

•        Clean work areas at the end of each shift or production run.

•        Participate in company 5S and housekeeping activities.

•        Immediately clean or report material, oil or water spillages.

Health & Safety Responsibilities

The General Helper must:

•        Follow all company Health & Safety rules and procedures.

•        Wear required Personal Protective Equipment (PPE) at all times.

•        Follow machine safety instructions.

•        Never remove or bypass machine guards or safety devices.

•        Never place hands or body parts into operating machinery.

•        Keep clear of hot dies, barrels, heaters and other hot surfaces.

•        Follow safe manual-handling practices when lifting pipes, materials and tooling.

•        Use lifting equipment where required.

•        Immediately report unsafe conditions, damaged equipment or unsafe behaviour.

•        Report all injuries, near misses and incidents immediately.

•        Follow emergency procedures and instructions.

•        Only operate machinery or equipment for which they have been trained and authorised.

General Duties

•        Follow instructions issued by the Extrusion Operator, Supervisor and Management.

•        Assist other Extrusion Department employees when required.

•        Assist with stock counts and production counts where required.

•        Assist Maintenance personnel during maintenance activities when instructed and safe to do so.

•        Participate in production meetings, toolbox talks and training.

•        Follow company policies, procedures, SOPs and Work Instructions.

•        Perform other reasonable factory duties related to the position when requested by Management.

Minimum Requirements

•        Basic secondary education preferred.

•        Ability to read and understand basic instructions.

•        Basic numerical ability.

•        Ability to count and record production quantities accurately.

•        Physically capable of performing general factory duties.

•        Able to work safely within a manufacturing environment.

•        Previous factory or manufacturing experience would be an advantage.

•        Previous experience in PVC or PE pipe extrusion, plastics manufacturing or a similar production environment would be an advantage but is not essential.

Training will be provided for suitable candidates.

Required Skills

The employee should demonstrate:

•        Ability to follow instructions.

•        Good attention to detail.

•        Basic numerical skills.

•        Good teamwork.

•        Good communication.

•        Ability to work safely.

•        Ability to perform physical production activities.

•        Good housekeeping habits.

•        Willingness to learn.