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 .