Senior Engineer - Production

JOB DESCRIPTION Position Details Particulars Details Position Senior Engineer – Production Location Hosur, Tamil Nadu Qualification Diploma / Any Degree Experience 3–5 Years Reporting To R. Naveen Kumar Function Production / Manufacturing Role Summary The Senior Engineer – Production will be responsible for managing end-to-end production operations for foam processing and roll-pack mattress manufacturing . The role will ensure achievement of production targets while maintaining quality, productivity, safety, material efficiency, and on-time delivery. The position will oversee operations from foam cutting and processing through assembly, compression, roll packing, packing, and dispatch , while driving continuous improvement and lean manufacturing initiatives. Key Responsibilities 1. Production Operations Manage end-to-end production operations for foam cutting, processing, assembly, compression, roll packing, packing, and dispatch. Ensure achievement of daily, weekly, and monthly production targets. Monitor production flow and ensure uninterrupted operations. Ensure production is carried out as per approved SOPs, BOMs, specifications, and production plans. 2. Production Planning & Execution Plan daily and monthly production based on customer requirements, sales orders, capacity, and material availability. Coordinate with PPC to align production plans with business requirements. Monitor production achievement against planned targets and take corrective actions for deviations. Ensure timely completion of production to support on-time dispatch. 3. Foam Cutting & Processing Supervise foam cutting, profiling, gluing, assembly, compression, and rolling operations. Ensure correct foam dimensions, density, firmness, thickness, and other product specifications as per BOM and customer requirements. Optimize cutting patterns to improve foam yield and material utilization. Monitor and control foam wastage and process losses. 4. Productivity & Capacity Management Monitor machine capacity, manpower utilization, line balancing, takt time, cycle time, and production efficiency. Identify bottlenecks and implement corrective actions to improve throughput. Monitor OEE, productivity, downtime, rejection, rework, and production efficiency. Drive initiatives to improve labour and machine utilization. 5. Quality & Process Control Ensure adherence to defined quality standards and product specifications. Monitor rejection, rework, process deviations, and customer-related quality issues. Conduct root-cause analysis and implement corrective and preventive actions. Ensure proper implementation of SOPs, process controls, and quality checkpoints. 6. Lean Manufacturing & Continuous Improvement Implement and sustain Lean Manufacturing, 5S, Kaizen, SMED, Visual Management, and Standard Work practices. Identify opportunities for productivity improvement, waste reduction, and process optimization. Lead continuous improvement projects to improve production efficiency and reduce manufacturing costs. Standardize improved processes and ensure sustained implementation. 7. Manpower Management Plan and allocate manpower based on production requirements and workload. Manage shift planning and workforce deployment. Train team members on processes, SOPs, quality, safety, and productivity standards. Monitor employee performance, productivity, skill levels, and attendance. Identify training and skill-development requirements. 8. Cross-Functional Coordination Coordinate with PPC, Stores, Quality, Maintenance, Purchase, and Dispatch teams to ensure uninterrupted production. Ensure timely availability of raw materials, machines, manpower, and other resources. Escalate production constraints, material shortages, machine breakdowns, and quality issues to the concerned teams. Participate in daily production and cross-functional review meetings. 9. Production Reporting & Documentation Maintain accurate production records, shift reports, and performance reports. Prepare and maintain KPI dashboards using Excel / Google Sheets / SAP . Track production achievement, OEE, productivity, wastage, rejection, downtime, labour efficiency, and other operational metrics. Analyse production data and recommend improvement actions. 10. Cost & Efficiency Management Monitor and control manpower cost, material wastage, rejection, rework, and machine downtime. Drive initiatives to reduce cost per mattress without compromising quality. Improve material utilization and overall production efficiency. Ensure optimum utilization of manpower, machinery, and materials. 11. Safety & Compliance Ensure compliance with workplace safety standards and production safety procedures. Promote safe working practices across the production floor. Ensure proper use of PPE and adherence to safety guidelines. Maintain housekeeping and 5S standards within the production area. Key Areas of Responsibility Foam Cutting → Foam Processing → Assembly → Compression → Roll Packing → Packing → Dispatch Key Performance Indicators (KPIs) Production Achievement Foam Yield OEE Productivity Rejection % Rework % Material Wastage Machine Downtime Labour Efficiency On-Time Delivery Cost per Mattress Production Capacity Utilization 5S & Safety Compliance Required Skills & Competencies Strong knowledge of production and manufacturing operations . Experience in foam processing / mattress manufacturing will be preferred. Good understanding of production planning and shop-floor management. Knowledge of Lean Manufacturing, 5S, Kaizen, SMED, and process improvement. Strong analytical and problem-solving skills. Good understanding of OEE, productivity, yield, wastage, and downtime. Experience in manpower and shift management. Good working knowledge of MS Excel / Google Sheets / SAP . Strong communication and cross-functional coordination skills. Ability to work in a target-driven manufacturing environment. Education & Experience Qualification: Diploma or Any Degree Experience: 3–5 years of relevant experience in Production / Manufacturing Operations. Preferred: Candidates with experience in foam, mattress, furniture, bedding, or similar manufacturing industries . Note This Job Description is indicative of the roles, responsibilities, and duties to be performed by the employee. However, the Management reserves the right to add, delete, modify, or amend the Job Description based on business requirements.

• Experience: 3+ years
• Seniority: Mid Level
• Education: Bachelor's degree required
• Languages: English