Senior Production Manager

Location: Hosur, Tamil NaduReporting To: Plant HeadExperience: 15–20 YearsFunction: Manufacturing Operations

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.

• 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.

• 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.

• 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.

• 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.

• 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.

• 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.

• 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.

• 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

• Bachelor's Degree in Mechanical, Production, Industrial, or Manufacturing Engineering.

• Lean Six Sigma Green Belt or Black Belt certification is preferred.

• 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.

• 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

This role offers an exciting opportunity to lead a critical manufacturing function and play a strategic role in driving operational excellence. As a designated succession role for the Plant Manager position, it provides broad exposure to manufacturing leadership, safety, quality, productivity, cost optimization, industrial relations, and business transformation.

Focus Factory Manager / Senior Production Manager → Plant Manager