Senior Production Executive

Production Planning, Scheduling & Execution:

• Plan, implement, and monitor daily and weekly production schedules to achieve output targets on time and within budget.
• Review and dynamically adjust schedules based on machine availability, material readiness, and feeder department inputs.
• Coordinate closely with feeder departments (Machining, Material Cutting, Hardening, Coil Winding) to maintain smooth, bottleneck-free material flow.
• Reschedule delivery dates and setup routines in coordination with the Sales department when material availability varies.

Resource & Capacity Management:

• Allocate and manage manpower and equipment effectively to meet daily production goals.
• Make operational decisions regarding equipment usage, routine maintenance, modifications, and procurement needs.
• Review and approve all maintenance-related shop floor activities to minimize downtime.

Shop Floor & Manpower Leadership:

• Monitor staff performance, conduct time studies (updated with technology/process shifts), and organize targeted interventions for productivity improvement.
• Resolve shop floor blue-collar worker grievances directly; escalate unresolved issues promptly to Directors.
• Regulate visitor entry/exit policies on the shop floor to ensure strict security and compliance.

Quality Control & Customer Complaint Handling:

• Enforce an I Make, I Check quality culture across all assembly line stages.
• Coordinate with In-Process QC and Final QC to offer components/assemblies for inspection before final dispatch.
• Handle customer complaints in tandem with QC; implement Corrective and Preventive Actions (CAPA) immediately upon feedback.
• Partner with Quality and Sales to liaise with customers regarding specification adjustments or project scope modifications.

Cost Control, Rejection & Process Improvement:

• Implement cost-control programs to reduce material/consumable waste, lower process costs via Kaizens, and minimize scrap percentages.
• Track and report the Cost of Poor Quality (COPQ) to the Quality department at set intervals; intimate generated scrap immediately to In-process QC and Stores/Purchase.
• Target reductions in cycle times, changeover/setup times, electricity consumption, contract labor costs, and overall maintenance expenditures.

Key Performance Metrics & Resource Efficiency:

• Measure and report operational efficiency (operator, line, and machine performance) against targeted benchmarks; ensure line efficiency stays above baseline thresholds.
• Monitor and optimize machine utilization and compare allotted man-hours against actual man-hours used.
• Analyze production yields and complete physical reconciliations at every stage of manufacturing.

ERP, BOM Integrity & WIP Inventory Control:

• Ensure actual material consumption aligns strictly with Bill of Materials (BOM) specs; immediately update ERP BOMs in case of discrepancies.
• Track Non-BOM material consumption against production outputs and submit monthly reports to management.
• Monitor WIP stock continuously and lead quarterly WIP reconciliations (due on the 2nd working day of every quarter).
• Report mismatch values to Directors and coordinate SAN postings in ERP to align book stock with physical stock.
• Ensure proper back-flushing of materials at designated ERP declaration stages.

Compliance, Safety, 5S & SOPs:

• Develop, implement, and maintain Standard Operating Procedures (SOPs) for all production processes.
• Enforce strict compliance with ISO, ASME, CE, UL, CSA, safety protocols, and company policies.
• Lead and monitor weekly 5S activities across all work centers.
• Set KPIs for subordinates, prepare regular production reports, and ensure timely submission of management MIS.

• Education: Bachelor's degree in Mechanical or Production Engineering.
• Experience: 6 to 10 years of hands-on shop floor production experience in a precision manufacturing environment.
• Technical Mastery: In-depth knowledge of production scheduling, time studies, capacity planning, machine utilisation (OEE), scrap reduction, and assembly operations.
• Systems & Quality: Hands-on experience with ERP systems (BOM management/back-flushing), ISO/CE/UL standards, 5S, Kaizen, and CAPA methodologies.
• Leadership & Soft Skills: Strong conflict management capability for handling shop floor labour, analytical problem-solving, and clear cross-departmental communication skills.