Manager - Process Excellence & Cost Optimization

Job Purpose

This role controls plant cost and material loss and improves workforce productivity. It does this through standard measurement systems (BOM, cost per sq ft, manpower matrices) and shop-floor automation such as production scanning, smart scheduling and live dashboards.

Key Responsibilities

Cost and Financial Control

• Track monthly plant cost per sq ft against budget, and analyse and explain variances.
• Reconcile BB and COV material consumption and wastage against BOM, keeping variance within 1%.
• Build and maintain a BOM-based tracking system for general consumables, with cost variance within 5%.
• Reconcile and approve job-worker bills within the agreed billing cycle, with no delays.

Automation and Digital Tracking

• Implement operator-wise and team-wise production scanning (barcode for COV, QR code for BB) to measure throughput and reduce manpower cost by 10% YoY.
• Drive smart production scheduling and order-kit allocation to improve direct-worker efficiency by 20%.
• Develop an AI / Power BI tracker for media-wise material inflow versus wastage, with full traceability and variance under 1%.
• Maintain daily plant and department dashboards comparing budget and actual cost trends.

Waste Management and Manpower Productivity

• Develop at least two alternate or backup buyers for each saleable scrap item or category, targeting a 15% impact on sale value.
• Optimise waste disposal, including balers for cardboard, plastic and fabric, to cut waste volume by 30%.
• Build a manpower performance measurement matrix for non-sq-ft production and non-production departments.
• Support the skill matrix and skill-based operator allocation, and train supervisors and operators in method and productivity improvement (10 people per department).

General Duties

• Conduct time and motion studies, set standard times, and balance lines.
• Prepare monthly MIS and variance reports for management.
• Coordinate with production, stores, finance, IT and vendors.
• Lead Lean, Kaizen and 5S initiatives.

Qualifications and Experience

• B.E./B.Tech in Industrial, Mechanical or Production Engineering. An MBA or PGDIE is preferred.
• 8-12 years in manufacturing industrial engineering, costing or productivity, including at least 3 years leading projects or a team.

Skills and Competencies

• Strong in BOM and inventory reconciliation, cost analysis, time study and production scheduling.
• Skilled in advanced Excel and Power BI, with exposure to ERP/MES and barcode or QR systems. AI or analytics knowledge is a plus.
• Analytical, detail-oriented and comfortable presenting data to senior management.
• Able to work across departments and train shop-floor teams.