Production Manager - Cable Harness Manufacturing

Larsen & Toubro Ltd; Navavoor; On-site; INR 600,000 - 1,200,000; Full time

Job summary

Larsen & Toubro Ltd in Tamil Nadu is seeking a Production Manager to lead cable harnessing operations, planning daily, weekly and monthly production to meet customer demand and delivery commitments. You will oversee end-to-end processes from wiring through testing and packing.

You'll optimize manpower, machines and workflows based on takt time and production volume, ensure quality with Right First Time, drive continuous improvement (5S/Kaizen) and coordinate with Quality, Engineering, SCM and

Responsibilities

• Plan and execute daily, weekly and monthly production to meet customer demand and delivery schedules.
• Oversee end-to-end harness manufacturing: wire cutting, stripping, crimping, terminal insertion, routing, testing and packing.
• Optimize manpower, machines and workstation allocation based on takt time and production volume.
• Manage manpower, shifts, attendance coverage and operator productivity.
• Develop skills: maintain skill matrix, train, certify and multi-skill operators.
• Ensure quality: adhere to process controls and achieve Right First Time / zero defect production.
• Control crimping: maintain proper height, pull-force, tooling and validation.
• Oversee electrical testing: continuity, shorts/opens, insulation, Hi-Pot and functional tests.
• Maintain materials: ensure availability of wires, terminals, connectors, seals, tapes with FIFO and traceability.
• Manage equipment and tooling: ensure machine availability, PM, calibration and readiness.
• Support NPI and ECN: assist new product introduction, trials, validation and ramp-up.
• Document processes: BOM, SOP, WI, Control Plan, PFMEA and inspection standards.
• Drive continuous improvement: 5S, Kaizen, Poka-Yoke and Lean to reduce waste.
• Coordinate cross-functionally with Quality, Engineering, SCM, Maintenance, Planning, NPI and customers.
• Monitor KPIs: Plan vs Actual, Productivity, OEE, FPY, Rejection, Downtime and On-Time Delivery.

Job description

Production Manager - Cable Harnessing Roles & Responsibilities :

• Production Planning & Execution – Plan and execute daily, weekly and monthly production as per customer demand and delivery requirements.
• End-to-End Process Management – Manage complete harness manufacturing from wire cutting, stripping, crimping and terminal insertion to routing, taping, testing and packing.
• Capacity & Line Balancing – Optimize manpower, machines and workstation allocation based on takt time, cycle time and production volume.
• Manpower Management – Plan manpower deployment, shift allocation, absenteeism coverage and operator productivity.
• Skill Development – Maintain skill matrix and drive operator training, certification, multi-skilling and periodic skill evaluation.
• Quality Control – Ensure adherence to process controls and achieve Right First Time / Zero Defect production through in-process and final inspection.
• Crimping Process Control – Ensure proper crimp height, pull-force, terminal application, tooling condition and periodic crimp validation.
• Electrical Testing Management – Ensure continuity, short/open circuit, insulation resistance, Hi-Pot and functional testing requirements are effectively controlled.
• Material Management – Ensure availability of wires, terminals, connectors, seals, sleeves, tapes and other materials with proper FIFO and traceability.
• Equipment & Tooling Management – Ensure machine availability, preventive maintenance, calibration and readiness of cutting, stripping, crimping and testing equipment.
• NPI & Engineering Changes – Support new product introduction, trial builds, process validation, ECN implementation and production ramp-up.
• Process Documentation – Ensure effective implementation of BOM, SOP, WI, Control Plan, PFMEA, process parameters and inspection standards.
• Continuous Improvement – Drive 5S, Kaizen, Poka-Yoke, Lean Manufacturing, waste reduction and productivity improvement initiatives.
• Cross-Functional Coordination – Work closely with Quality, Engineering, SCM, Maintenance, Planning, NPI and Customer teams to resolve production issues.
• Performance & KPI Management – Monitor and improve Plan vs Actual, Productivity, OEE, FPY, PPM, Rejection, Rework, Downtime, Labor Efficiency and On-Time Delivery .