Process, Design & Costing( Manager or Sr. Manager)

Role & responsibilities

1. 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.

2. 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.

3. 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).

4. 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.

Key Deliverables

• Costing accuracy (variance between estimated vs. actual cost)
• Process yield improvement and scrap/wastage reduction
• Turnaround time for new product costing and process design release
• Cost savings achieved through value engineering / process optimization
• On-time NPD process readiness
• Team productivity and capability development

Required Qualifications & Skills

• B.E./B.Tech in Electrical, Electronics, Mechanical, Polymer or Production Engineering (Master's/MBA preferred).
• Strong technical knowledge of cable manufacturing processes: drawing, stranding, extrusion, insulation, sheathing, armoring, 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.

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