Purpose of the role:

Manufactures products by supervising staff, organizing and monitoring workflow. This position will be organizing, planning, and coordinating plant shop floor activities on a particular work shift. Supervises and coordinates activities of workers engaged in assembling parts or assemblies into valves, applying knowledge of assembly processes, tools, equipment, products, and production methods to build a valve. Reports to the production or manufacturing manager and provide them with detailed information about the daily production, quality, sales and shipping. The machining and assembly process is generally a part of the manufacturing process and usually includes the assembling of specific parts of the product and making it ready for dispatching. Closely working with third party inspectors and customer inspectors to offer the valves for inspection activities.

Key Responsibility:

Plan, schedule, and supervise daily assembly and testing operations to meet production targets and delivery commitments.

• Assign work to assembly technicians, testers, and helpers based on skill level and workload.

• Review job travelers, drawings, bill of materials, and work instructions prior to assembly to confirm correct configuration (port size, pressure class, trim material, end connections, operator type – gear/actuator/lever).

• Coordinate with machining, coating, and material handling departments to ensure smooth component flow into assembly.

• Monitor WIP (work-in-progress) and escalate bottlenecks or shortages to production planning.

Accountability & Authority

Accountability and direction of all direct and indirect work force. This includes the following activities:

• Provides ongoing supervision and motivation to the production ·

• Builds, motivates and retains a team that consistently meets production deadlines ·

• Responsible for the health and safety of his directly reporting employees and for ensuring a harassment-free environment in the production.

• Continuously evaluates production performance and focuses on continuous improvement in areas of opportunity/non-compliance · Assures good housekeeping practices (5S) through auditing

Core Competencies:

• Ensure proper assembly of plug valve components: body, plug/tapered or cylindrical, seats/sleeves, bushings, gland packing, thrust bearings, and actuation interfaces.

• Verify correct torque values, lubrication (sealant injection for lubricated plug valves), and lapping/seating procedures per engineering specs.

• Enforce use of calibrated torque wrenches, lapping compounds, and approved lubricants/sealants.

• Maintain traceability of critical components (heat numbers, material certs, seat/seal batch records).

• Testing & Quality Compliance

• Supervise hydrostatic (shell) testing, pneumatic/hydro seat testing, and low-pressure gas seat testing per applicable standards, including:

• API 598 – Valve Inspection and Testing

• API 6D – Pipeline and Piping Valves (for plug valves in pipeline service)

• API 599 – Metal Plug Valves

• ISO 5208 – Industrial valves – Pressure testing

• ASME B16.34– Valves – Flanged, Threaded, and Welding End

• MSS SP-78 – Cast Iron Plug Valves (where applicable)

• Customer/client-specific ITPs (Inspection & Test Plans) and datasheets

• Ensure test records (pressure, duration, hold time, leak rate) are accurately logged and signed off.

• Coordinate with QA/QC and third-party inspectors (TPI) for witnessed tests, hold points, and final release.

• Conduct root-cause analysis on test failures (seat leakage, body leakage, stem leakage) and drive corrective actions.

• Ensure NDE (Non-Destructive Examination) requirements, where applicable, are completed prior to final assembly.

Documentation

• Complete and review assembly/test records, non-conformance reports (NCRs), and material traceability documentation.

• Maintain calibration records for torque wrenches, pressure gauges, and test bench instrumentation.

• Support preparation of data books/dossiers for customer submission.

Team & Safety Management

• Supervise, train, and mentor assembly and testing technicians on procedures, standards, and safe work practices.

• Enforce PPE use and safe handling of pressurized test equipment.

• Conduct toolbox talks and ensure compliance with company HSE policies during hydro/pneumatic testing.

• Manage attendance, performance evaluations, and skill development plans for the team.

Continuous Improvement

• Identify opportunities to reduce cycle time, rework, and test failures.

• Support implementation of lean manufacturing / 5S practices in the assembly and test area.

• Participate in internal audits and support ISO 9001 / API Q1 quality management system compliance.

Qualifications & Experience:

• Diploma or bachelor’s degree in mechanical engineering or related field (or equivalent hands-on experience).

• Minimum 5–8 years of experience in valve manufacturing, with at least 2–3 years in a supervisory role in assembly/testing.

• Hands-on experience specifically with plug valves preferred (lubricated/non-lubricated, sleeved).

• Strong working knowledge of API 598, API 6D, API 599, ISO 5208, ASME B16.34, and MSS standards.

• Familiarity with reading GA drawings, cross-sectional drawings, and P&IDs.

• Understanding of materials (carbon steel, stainless steel, duplex, Monel, etc.) and their relevance to sealing and testing.

• Knowledge of torque specifications, gasket/seal installation, and pressure test equipment operation.

• Strong leadership and team management skills.

• Problem-solving and root-cause analysis capability.

• Good communication skills for coordinating with QA, engineering, and TPI/customers.

• Proficiency with basic MS Office / SAP ERP systems for job tracking and reporting.