Manager – Process Design & Costing - Wire & Cable

Sone India; Bhiwadi; On-site; INR 4,000,000 - 7,000,000; Full time

Job summary

Sone India is seeking a senior Process Design & Costing Leader to own end-to-end process design and costing across cable products. You will drive NPD process design, establish SOPs, and lead cross-functional teams to optimize throughput, cost, and quality in a dynamic manufacturing environment.

The role requires deep expertise in cable manufacturing processes, strong costing acumen, and leadership skills to manage a multi-disciplinary team and coordinate with Production, Quality, R&D,

Qualifications

• Bachelor’s degree in Electrical, Electronics, Mechanical, Polymer or Production Engineering (MBA preferred).
• 12–18 years in wire & cable manufacturing with at least 5 years in process design or costing leadership.
• Experience across LAN, power, house wire, instrumentation cables and cable assemblies.

Responsibilities

• Establish and own end-to-end process flow designs for LAN, power, house wire, instrumentation cables and cable assemblies.
• Define machine-wise process parameters, line speeds, tooling and die specifications for new products and customer approvals.
• Approve process route cards, work instructions and SOPs before release to production.
• Lead process improvement, automation and de-bottlenecking to enhance throughput, yield and first-pass quality.
• Review and approve process changes due to new materials, machine upgrades or customer spec changes.
• Drive New Product Development (NPD) process design from concept to mass production readiness.

Skills

Process design leadership

Costing management

ERP systems

MS Excel

Cross-functional leadership

Regulatory standards knowledge

Education

B.E./B.Tech in Electrical, Electronics, Mechanical, Polymer or Production Engineering

Tools

Costing software

Job description

Key Responsibilities

• Process Design & Engineering Leadership
  • Establish and own end-to-end process flow designs (drawing, stranding, insulation extrusion, sheathing, armouring, cabling, and assembly operations) for LAN, power, house wire, instrumentation cables and cable assemblies.
  • Define machine-wise process parameters, line speeds, tooling and die specifications for new products and new customer approvals.
  • Approve process route cards, work instructions and standard operating procedures (SOPs) before release to production.
  • Lead process improvement, automation and de-bottlenecking initiatives to enhance throughput, yield and first-pass quality.
  • Review and approve process changes arising from new raw materials, machine upgrades or customer specification changes.
  • Drive New Product Development (NPD) process design from concept/sample stage through to mass production readiness.
• Costing & Commercial Support
  • Own the standard costing framework (material, conversion, overhead) for all product categories and ensure it is updated in line with input cost movements (copper, aluminium, PVC, XLPE, PE, etc.).
  • Review and approve product costing sheets, BOM-based cost builds and quotations for new enquiries, tenders and key accounts.
  • Provide costing inputs for pricing decisions, margin analysis and profitability reviews in coordination with Sales, Marketing and Finance.
  • Benchmark costs against competitors and industry standards; identify and lead cost-reduction and value-engineering projects.
  • Validate costing impact of engineering changes, alternate raw materials, and process modifications.
• Cross-Functional Coordination
  • Work closely with Production, Quality, R&D, Procurement, Sales and Finance to ensure process and cost data integrity across the value chain.
  • Coordinate with Procurement on raw material specifications, alternate vendor qualification and cost-saving substitutions.
  • Support Sales/Business Development with technical-commercial inputs for tenders, RFQs and customer negotiations.
  • Liaise with R&D and Quality on new product qualification, testing requirements and regulatory/standard compliance (BIS, IS, IEC, UL, RoHS as applicable).
• Team Leadership & Governance
  • Lead, mentor and develop the Process Design & Costing team, including Executives and Engineers.
  • Set departmental KPIs/targets, review performance and build technical capability within the team.
  • Establish document control, version management and audit trail for all process design and costing records.
  • Ensure compliance with ISO/quality management system requirements relevant to process and costing documentation.
  • Present periodic reports to senior management on cost trends, margin performance, process efficiency and improvement initiatives.

Qualifications

• B.E./B.Tech in Electrical, Electronics, Mechanical, Polymer or Production Engineering (Master's/MBA preferred).

Experience

• 12-18 years of experience in the wire & cable manufacturing industry, with at least 5 years in a process design and/or costing leadership role.
• Proven experience across multiple cable categories - LAN, power, house wire, instrumentation cables and cable assemblies - preferred.

Skills & Competencies

• Strong technical knowledge of cable manufacturing processes: drawing, stranding, extrusion, insulation, sheathing, armouring, testing.
• Expertise in product costing, BOM structuring and cost-benefit analysis.
• Working knowledge of relevant standards (IS, IEC, BIS, UL, RoHS) and raw materials used in cable manufacturing.
• Proficiency in ERP systems, MS Excel and costing/estimation tools.
• Strong leadership, cross-functional coordination and decision-making skills.
• Analytical mindset with a continuous improvement and cost-consciousness orientation.