Senior Production Manager

Duroflex; Krishnagiri District; On-site; INR 3,500,000 - 5,500,000; Full time

Job summary

Duroflex is seeking a Focus Factory Manager / Senior Production Manager to lead end-to-end mattress conversion at Hosur plant. You will oversee quilting, wadding, stitching, packaging, and more, driving safety, quality, delivery, and cost performance in a large unionized shop floor.

The role requires 15+ years in manufacturing with at least 5 years in leadership for mattress/conversion operations, plus Lean/IE expertise.

Qualifications

• 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.
• Strong exposure to Lean Manufacturing, Industrial Engineering, and continuous improvement methodologies.

Responsibilities

• 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.
• 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.
• Drive First-Time-Right (FTR) performance and establish CTQ standards.
• Minimize defects, rework, and customer complaints through robust quality systems.
• Lead structured problem-solving and root cause analysis initiatives.
• 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.
• Lead Lean Manufacturing initiatives including 5S, Kaizen, 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.
• 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.
• 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.

Skills

Mattress Conversion

Quilting & Wadding

Stitching Operations

Industrial Sewing Systems

Lean Manufacturing

Time & Motion Study

Value Stream Mapping

Production Planning

Capacity Management

Cost Optimization

Team Leadership

Industrial Relations

Education

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

Lean Six Sigma Green Belt or Black Belt certification

Job description

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.

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)

Throughput & Capacity Utilization

First-Time-Right (FTR) Quality

Industrial Relations Stability

Productivity & Cost Savings

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.

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

Technical Skills

Mattress Conversion Processes

Quilting & Wadding

Tape Edge & Stitching Operations

Industrial Sewing Systems

Lean Manufacturing

Time & Motion Study

Value Stream Mapping (VSM)

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.

Focus Factory Manager / Senior Production Manager Plant Manager