Manager - Industrial Engineering

Job Title: Manager Industrial Engineering
Location: Madurai

Role Purpose:

To ensure that standards of production and working methodology are maintained and improved to deliver best practice in results of efficiency and labour utilization. Identify opportunities to improve the site operations in terms of throughput times, service and productivity enhancement to deliver World Class performance.

To support the site manufacturing department and warehousing operations through the creation and implementation of clear, well defined IE standards that can be used to support the continuous improvement process.

Principal Accountabilities:

Set & Manage Industrial Engineering Standards:

• Ensure that IE standards of production and working methodology as per work measurement studies, provide zero base standards for every work centre in Site manufacturing department.
• Ensure industrial engineering standards are developed and being applied within the manufacturing floor Spinning and Twisting with gaps identified, documented and communicated. A monthly report should be in place to document the gaps between the standard and the actual practice for each department. [head count, allocations].
• Work out Mhrs and Lhrs for all thread qualities.
• Work out manning requirement based on log plan for all work centres, circulate to all stake holders for their actions to trim the manning in line with Zero-base. Assist in the compilation and calculation of the P15 and Strategies to identify manning and capital expenditure requirements.
• Prepare OHK reconciliation report on monthly basis and narrow down the gap between Zero base Vs Actual.
• Generate GT reconciliation report to understand the details between system consumption and standard consumption. Take initiatives to monitor the GKG revision and performance on a monthly basis.
• Develop timely and accurate reporting of relevant KPI’s and manufacturing monitoring
• Drive continuous improvement to maximise output in all manufacturing areas & Develop and Assist in implementation of continuous improvement initiatives.
• Support other managers in introducing new working methodology and procedures.
• Training of employees on LSS, IE, 5S, correct working practices to deliver consistent excellence in performance.
• Improve working practices to achieve reduced material consumption through reduced wastage and non-conformity within the process.
• Assist Sr. Manager IE to Roll out best practice I.E. and Lean Manufacturing concepts to other units to achieve pan-India improvement.

Drive & Manage Continuous Improvement Process:

• Continually drive productivity and efficiency improvement through the adoption of A3 charter, LSS techniques, including DMAIC processes.
• Drive manufacturing productivity improvement ideas, quick hits, kaizen projects & LSS projects thereby achieve targeted numbers y-o-y.
• Ensure all new projects are entered on the Power Steering project management facility, taken from hopper ideas through to full projects that are monitored throughout the month and updated monthly in line with the group reporting requirements
• Ensure the integrity of all data used for the calculation of plant wide incentive schemes.
  
  

Activity Description:

• Monitor attainment of the annual production plan
• Identify the internal factors, which may affect the attainment of production output.
• Review working methods in order to optimize them
• Analyse the organization of production in order to improve it
• Analyse the working time structure of machines
• Determines working time of the operations (rate setting)
• Audit the working norms compliance through production operators
• Calculate variations for future production plans, calculation of machine and Operator hours and therefore machine and labour utilisation
• Guides the multi-skill and training activity of operators in collaboration with the Trainer and Development Coordinator

Education, Qualifications and Experience:

• Professional graduate in the area of industrial engineering or similar areas in a science-based discipline
• Minimum 10 years relevant work experience which include time and motion study
• Experience in conducting risk assessment and is JSA beneficial
• Experience in value stream mapping advantageous
• Must possess knowledge of Project management.
• KPIs for cost, productivity, waste, and digitalization.
• Team management experience- Local legislation for worker routines, incentive pay, work loading
• Understanding of factory wide incentive schemes and calculations
• Coats Health and Safety policies and procedures
• Knowledge of Coats operational SOP that influence IE standards
• Understanding of Lean Six Sigma toolbox up to BB/MBB level  

Desirable:

• Clear cost-reduction ownership
• Structured loss-tree analysis responsibility
• Basic automation/digital skills (Power Automate, basic SQL, etc.).
• IE team capability roadmap and coaching expectations.
• Stronger cross-functional leadership for change management.
• Digital work measurement skills.
• Knowledge or qualification- Lean Six Sigma Techniques’ BB/MBB

At Coats Group, we are committed to innovation, excellence, and fostering a diverse and collaborative environment where every team member can thrive. If you are passionate about making an impact in the textile industry and eager to join a global leader with a rich heritage and a forward-thinking approach, we invite you to take the next step in your career with us.