Cutting & Sorting Manager

Job Description: Cutting Department ManagerDepartmentCutting & SortingJob PurposeTo manage the complete throughput of the Cutting Department including cutting machines, manual cutting, and the sorting team — by ensuring high people productivity, optimal machine efficiency, minimal fabric and foam wastage, timely order execution based on ageing, accurate cut-kit dispatch to vendors, and error-free cutting and sorting to eliminate kit returns.
Key Responsibilities1. Throughput & Productivity Management

• Own end-to-end throughput of all cutting machines and the sorting team.
• Monitor and drive machine efficiency (OEE) and operator productivity on a daily/shift basis.
• Track output vs. plan for cutting and sorting; identify and resolve bottlenecks in real time.
• Set and review productivity benchmarks (pieces/hour, kits/day, machine utilization %) for operators and machines.

2. Cutting Operations (Fabric, Foam & Manual)

• Plan and supervise fabric cutting, foam cutting, and manual cutting operations.
• Deploy manual cutting judiciously for small-scale/low-volume requirements to optimize material usage and reduce wastage.
• Continuously identify opportunities to reduce fabric and foam wastage through better marker planning, lay optimization, and cutting sequence.
• Ensure correct cutting specifications, patterns, and sizes are followed as per order requirements.

3. Order Prioritization & Scheduling

• Track ageing of all pending orders and use ageing data to prioritize the daily/weekly cutting schedule.
• Prepare and maintain a cutting schedule/plan aligned with dispatch commitments and order priority.
• Coordinate with planning, merchandising, and production teams to align cutting schedules with overall production flow.

4. Sorting & Kit Management

• Supervise the sorting team to ensure accurate sorting and kitting of cut components.
• Ensure cut kits are complete, correctly matched, and free of defects before dispatch.
• Ensure cutting and sorting processes are executed error-free to eliminate kit returns from vendors/downstream units.

5. Vendor Kit Distribution

• Ensure cut kits are distributed to vendors strictly as per the agreed dispatch plan and timelines.
• Maintain proper documentation and records of kits dispatched — including quantity, date, vendor, and order reference.
• Coordinate with logistics/dispatch teams to ensure timely and accurate handover of kits.
• Track and resolve any discrepancies or delays in kit distribution.

6. Quality & Wastage Control

• Implement checks/controls to minimize cutting errors, mismatches, and material wastage.
• Conduct root-cause analysis on kit returns or cutting errors and implement corrective/preventive actions.
• Drive continuous improvement initiatives to reduce rework, wastage %, and kit rejection rate.

7. Team Management

• Lead, train, and manage cutting machine operators, manual cutters, and the sorting team.
• Plan manpower deployment/shift allocation based on order load and machine availability.
• Monitor attendance, discipline, and performance of the team; conduct performance reviews.
• Identify training needs and build a skilled, multi-tasking workforce.

8. Records & Reporting

• Maintain accurate records of cutting output, wastage, machine efficiency, kit dispatch, and returns.
• Prepare and share daily/weekly/monthly MIS reports with management on department performance.
• Ensure documentation is audit-ready and compliant with internal SOPs.

9. Machine & Resource Management

• Ensure preventive maintenance of cutting machines is planned and executed to avoid downtime.
• Coordinate with maintenance team for timely breakdown resolution.
• Monitor machine efficiency and take corrective action for underperforming equipment.

Key Result Areas (KRAs)

• Cutting & sorting throughput vs. plan
• Machine efficiency / OEE %
• Fabric & foam wastage %
• On-time cut-kit dispatch to vendors (%)
• Kit return rate (target: zero/near-zero)
• Order ageing compliance in scheduling
• Team productivity and attendance
• Accuracy of dispatch and production records

Qualifications & Experience

• Graduate in Textile/Mechanical, Production, Industrial Engineering, or related field (relevant experience may be considered in lieu).
• 5–10 years of experience in cutting department operations within furniture, mattress, upholstery, garment, or foam-based manufacturing.
• Proven experience managing cutting machines (fabric/foam) and sorting/kitting teams.
• Hands-on exposure to manual cutting operations is preferred.

Skills & Competencies

• Strong understanding of fabric and foam cutting processes and wastage optimization techniques.
• Good planning and scheduling skills, especially order-ageing-based prioritization.
• People management and team leadership skills.
• Data-driven approach — comfortable maintaining records/MIS in Excel or ERP systems.
• Strong coordination skills with planning, merchandising, dispatch, and vendor teams.
• Problem-solving mindset with focus on quality and error elimination.
• Attention to detail and process discipline.