Senior Consultant at Ad Astra Consultants
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Production Manager (10-20 yrs)
The Production Manager is responsible for end-to-end manufacturing execution of fiber optic cable assemblies, ensuring on-time delivery, quality compliance, productivity, and cost efficiency in a contract manufacturing environment.
The role involves managing shop-floor operations, manpower, equipment, and processes, while closely coordinating with Planning, Quality, Engineering, SCM, and Customer Support teams to meet customer commitments and business objectives.
Key Responsibilities & KRAs
1. Production Execution & Delivery
Objective: Achieve consistent on-time delivery with optimal utilization of resources.
Responsibilities
- Execute daily, weekly, and monthly production plans for fiber optic cable assemblies
- Ensure adherence to production schedules and customer delivery commitments
- Manage multiple product variants, customers, and priority changes
- Coordinate with Planning for plan adjustments and capacity alignment
- Drive throughput and minimize bottlenecks across critical processes
2. Shop Floor & Manpower Management
Objective: Maintain efficient, disciplined, and safe shop-floor operations.
Responsibilities
- Manage operators, supervisors, and line leaders across shifts
- Ensure optimal manpower allocation and skill utilization
- Monitor attendance, productivity, and training needs
- Enforce discipline, safety, and standard work practices
- Support skill development and multi-skilling of operators
3. Process Control & Quality Compliance
Objective: Ensure products meet customer and industry quality standards.
Responsibilities :
- Ensure compliance with approved work instructions, SOPs, and control plans
- Monitor in-process quality and adherence to fiber optic standards
- Support root cause analysis for defects, rework, and customer complaints
- Coordinate with Quality for audits, corrective actions, and process improvements
- Drive right-first-time manufacturing
4. Equipment, Tools & Maintenance Coordination
Objective: Ensure high equipment availability and process reliability.
Responsibilities
- Ensure proper usage and upkeep of production equipment and tools
- Coordinate preventive maintenance and breakdown support
- Support commissioning of new machines, jigs, fixtures, and automation
- Drive improvements in equipment uptime and OEE
5. Continuous Improvement & Cost Optimization
Objective: Improve efficiency, reduce waste, and control manufacturing costs.
Responsibilities
- Implement Lean Manufacturing practices (5S, Kaizen, SMED, Poka-Yoke)
- Identify and eliminate non-value-added activities
- Drive productivity improvement and cost reduction initiatives
- Support automation and industrial engineering projects
- Track and sustain improvement benefits
6. Cross-Functional Coordination
Objective: Ensure seamless execution through collaboration.
Responsibilities :
- Work closely with Planning, SCM, Engineering, Quality, and Customer Support
- Support NPI, pilot builds, and ramp-up of new products
- Participate in daily production meetings and escalation reviews
- Support customer visits and audits
7. Safety, Compliance & Discipline
Objective: Maintain a safe and compliant manufacturing environment.
Responsibilities :
- Ensure adherence to EHS policies and statutory requirements
- Conduct safety briefings and audits
- Enforce discipline and shop-floor housekeeping standards
- Support ISO / TL9000 / customer compliance requirements
Required Qualifications Education :
- Bachelor's degree in Mechanical, Electrical, Electronics, or Manufacturing Engineering
- Diploma with strong manufacturing experience may be considered
Experience :
- 10- 15 years of manufacturing experience, including 3- 5 years in a leadership role
- Mandatory experience in contract manufacturing
- Exposure to fiber optic cable assembly, electronics, or telecom manufacturing strongly preferred
Skills & Competencies :
- Strong understanding of fiber optic cable assemblies, connectors, polishing, and testing
- Hands-on production management and problem-solving ability
- Knowledge of Lean Manufacturing and shop-floor best practices
- Ability to manage high-mix, low-to-medium volume production
- ERP/MRP system exposure
- Strong leadership, communication, and execution skills

