Manager - Process Excellence & Cost Optimization

Group Bayport; Gandhinagar; On-site; INR 1,800,000 - 3,000,000; Full time

Job summary

Group Bayport seeks a Manager for Process Excellence & Cost Optimization to lead cost control programmes, optimize material usage and improve productivity on the shop floor. You will implement barcode/QR based tracking, automate scheduling, and develop AI-driven dashboards to monitor variances and drive efficiency.

The role requires strong analytical skills, leadership experience, and hands-on Lean/5S expertise.

Qualifications

• 8–12 years in manufacturing industrial engineering, costing or productivity, incl. 3+ years leading projects or a team.
• B.E./B.Tech in Industrial, Mechanical or Production Engineering; MBA or PGDIE preferred.

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%.
• Reconcile and approve job-worker bills within the billing cycle with no delays.
• Implement operator-wise production scanning (barcode) 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 AI/Power BI tracker for material inflow vs wastage with variance under 1%.
• Maintain daily dashboards comparing budget and actual cost trends.
• Lead Lean, Kaizen and 5S initiatives.

Skills

BOM reconciliation

Cost analysis

Time study

Production scheduling

Advanced Excel

Power BI

ERP/MES exposure

Barcode/QR systems

AI/analytics knowledge

Education

B.E./B.Tech in Industrial Engineering

MBA or PGDIE preferred

Tools

ERP/MES

Barcode/QR systems

Job description

Manager - Process Excellence & Cost Optimization

8+ Years

Full-Time

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.