Sr. Production Engineer (Foam)

Job Description

Company Profile:

A leading foam and wiring harness manufacturing company specializing in the design, development, and production of high-quality cable assemblies and electrical wiring solutions for diverse industrial applications.

Position Overview:

The Sr. Production Engineer (Foam) will be responsible for driving production planning, process efficiency, and inventory control within the foam manufacturing unit. The role requires a hands-on leader who can optimize manpower, machinery, and material utilization while ensuring consistent quality, cost control, and on-time delivery. The incumbent will play a key role in driving continuous improvement initiatives and cross-functional coordination to support overall plant performance.

Qualifications:

• B.E. / B.Tech in Mechanical Engineering, MBA (Production), or Diploma in Mechanical Engineering
• 8–15 years of relevant experience in Foam, Rubber, Plastics, or Automotive manufacturing
• Prior experience in a similar production leadership role within a manufacturing setup

Key Responsibilities:

• Develop and manage production schedules to meet customer demand while optimizing manpower, machinery, and materials
• Control raw material and finished goods inventory, reviewing monthly stock variances
• Drive production cost control and efficiency, targeting OEE >80% and OLE >90%
• Lead Kaizen initiatives and process improvement projects for operational excellence
• Coordinate cross-functionally with procurement, logistics, and maintenance teams
• Utilize production data and analytics to support forecasting and decision-making
• Ensure compliance with safety standards and applicable industry regulations
• Monitor weekly sales reviews, maintaining sales compliance above 90% and tracking delivery losses
• Participate in MRM, YTT, Budget Reviews, and Management Meetings

Skills Required:

• Strong expertise in Production Planning & Control (PPC), including scheduling and resource optimization
• Hands-on knowledge of PU Foam manufacturing processes — gumming, cutting, and stitching
• Practical experience in Lean Manufacturing and Kaizen methodologies to drive efficiency
• Working proficiency in SAP Business One / ERP systems for production and inventory management
• Strong leadership and cross-functional coordination skills with procurement, logistics, maintenance, and OEM/B2B stakeholders

Special Requirements:

• In-depth knowledge of PU Foam manufacturing, including gumming, cutting, and stitching processes
• Mandatory hands-on experience with SAP Business One in production and inventory functions
• Proven ability to lead and manage shop-floor teams effectively
• Experience coordinating with suppliers and OEM/B2B customers
• Strong computer proficiency with MIS reporting and presentation skills