Position: Focus Factory Manager / Senior Production Manager

Location: Hosur, Tamil Nadu

Reporting To: Plant Head

Experience: 15–20 Years

Function: Manufacturing Operations

About the Role

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.

Key Responsibilities

Manufacturing Operations

- 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.

Safety & Compliance

- 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.

Quality Management

- 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.





Productivity & Cost Optimization

- 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.

Lean Manufacturing & Industrial Engineering

- 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.

People Leadership

- 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.

Industrial Relations

- 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.

Key Performance Indicators (KPIs)

- 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

Qualifications

Education

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

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

Experience

- 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.

- Robust exposure to Lean Manufacturing, Industrial Engineering, and continuous improvement methodologies.

Technical Skills

- 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

Why Join Us?

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.

Career Progression

Focus Factory Manager / Senior Production Manager → Plant Manager

📌 Senior Production Manager (Tamil Nadu)
🏢 Duroflex Group
📍 Tamil Nadu