Senior Production Manager

Job description

Job Description Position: Focus Factory Manager / Senior Production Manager **Location:** Hosur, Tamil Nadu **Reporting To:** Plant Head **Experience:** 15-20 Years **Function:** Manufacturing Operations About the Role We are looking for a highly driven **Focus Factory Manager / Senior Production Manager** to lead our end-to-end Mattress Conversion operations at our Hosur manufacturing facility. This is a strategic leadership role responsible for driving excellence across Safety, Quality, Delivery, Cost, and People (SQDCP) while ensuring world-class manufacturing standards. The incumbent will own the complete conversion value stream - from raw material processing to finished mattress packaging - and lead a large shop-floor workforce in a unionized manufacturing environment. This position is a high-potential succession role for the future Plant Manager position. Key Responsibilities - Lead end-to-end mattress conversion operations including Quilting, Wadding, Spring Production (Bonnell & Pocket), Stitching, Tape-Edge, Finishing, and Packaging. - Ensure adherence to production plans while maximizing throughput, machine utilization, and capacity. - Drive line balancing, production efficiency, and workflow optimization across manufacturing lines. Safety & Compliance - Foster a Zero Incident safety culture across all manufacturing operations. - Ensure compliance with statutory regulations, safety standards, and machine safety practices. - Promote employee participation in workplace safety initiatives. Quality Management - Drive First-Time-Right (FTR) performance and establish Critical-to-Quality (CTQ) standards. - Minimize defects, rework, and customer complaints through robust quality systems. - Lead structured problem-solving and root cause analysis initiatives. Productivity & Cost Optimization - Improve labor productivity and reduce conversion costs through operational excellence. - Optimize manpower utilization, material consumption, and overall production efficiency. - Support annual budgeting, cost control, and productivity improvement initiatives. Lean Manufacturing & Industrial Engineering - Lead Lean Manufacturing initiatives including 5S, Kaizen, Value Stream Mapping (VSM), TPM, and waste elimination. - Conduct line balancing, time and motion studies, and workflow optimization. - Drive continuous improvement projects to enhance productivity and operational excellence. People Leadership - Lead, mentor, and develop supervisors, engineers, and shop-floor teams. - Build a culture of accountability, discipline, engagement, and continuous learning. - Develop succession plans and strengthen workforce capability. Industrial Relations - Maintain healthy industrial relations in a unionized environment. - Resolve employee grievances proactively while ensuring workforce stability. - Collaborate with cross-functional teams to support automation, capacity expansion, and operational improvements. Key Performance Indicators (KPIs) - Zero Lost Time Injury (LTI) - Throughput & Capacity Utilization - Operator Labor Efficiency (OLE) - First-Time-Right (FTR) Quality - CTQ Defect Reduction - 5S & Kaizen Performance - Industrial Relations Stability - Productivity & Cost Savings - Conversion Cost per Unit Qualifications Education - Bachelor's Degree in Mechanical, Production, Industrial, or Manufacturing Engineering. - Lean Six Sigma Green Belt or Black Belt certification is preferred. Experience - 15+ years of manufacturing experience in assembly-line operations. - Minimum 5 years of leadership experience in Mattress Conversion, Textile Manufacturing, Soft Goods Manufacturing, Furniture Manufacturing, Made-ups, or Stitching Operations. - Experience managing large teams in a unionized manufacturing environment. - Strong exposure to Lean Manufacturing, Industrial Engineering, and continuous improvement methodologies. Technical Skills - Mattress Conversion Processes - Quilting & Wadding - Bonnell & Pocket Spring Production - Tape Edge & Stitching Operations - Industrial Sewing Systems - Lean Manufacturing - Industrial Engineering - Line Balancing - Time & Motion Study - Value Stream Mapping (VSM) - 5S, Kaizen & TPM - Root Cause Analysis - Production Planning & Capacity Management - Cost Optimization - Team Leadership & Industrial Relations Disclaimer: This job posting has been aggregated from external source. Role details, content, and availability are subject to change. Applicants are advised to confirm the latest information directly on the company website before applying.