Manager - Process Excellence And Cost Optimization

Group Bayport; Gandhinagar; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Group Bayport in Gandhinagar seeks an experienced Industrial/Production Engineer to control plant costs, optimise BOM usage and boost productivity. You will drive cost tracking, waste reduction and KPI dashboards using Power BI and ERP/MES systems.

You will lead lean projects, implement shop-floor automation, and mentor shop-floor teams across departments, ensuring accuracy in time studies, scheduling and cost variance management.

Qualifications

• BE/BTech in Industrial, Mechanical or Production Engineering.
• MBA or PGDIE is preferred.
• 8–12 years in manufacturing engineering and productivity roles, incl. 3+ years leading projects or a team.

Responsibilities

• Track monthly plant cost per sq ft against budget and explain variances.
• Reconcile material consumption and wastage against BOM with variance within 1%.
• Build BOM-based tracking for consumables with cost variance within 5%.
• Lead Lean, Kaizen and 5S initiatives; train and mentor shop-floor teams.

Education

B.E./B.Tech in Industrial/Mechanical/Production

MBA or PGDIE preferred

Tools

Power BI

ERP/MES

Barcoding systems

Job description

Job Description:

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.