Sofa Production Manager

Role Purpose:

The Production Manager is responsible for end-to-end management of sofa manufacturing operations, ensuring achievement of daily/weekly/monthly production targets with high quality, optimal cost, and safe working practices. The role involves managing supervisors, manpower, materials, equipment, and cross-functional coordination while continuously improving productivity, efficiency, and line discipline.

Key Responsibilities:

1. Production Planning & Execution

• Develop and execute daily and weekly production plans in alignment with demand and capacity.

• Ensure smooth functioning of conveyor lines and workstations across assembly, foaming, upholstery, and finishing.

• Monitor hourly and shift-wise output against targets; take corrective actions in case of deviations.

• Resolve bottlenecks by coordinating with maintenance, planning, and quality teams.

• Drive OEE improvement across lines.

2. Quality Assurance

• Ensure adherence to SOPs, work instructions, quality standards, and in-process checks.

• Monitor quality at all stages, frame assembly, foaming, stitching, upholstery, and final inspection.

• Reduce rework and rejection through root cause analysis and preventive actions.

• Drive First-Time-Right (FTR) production through training and process discipline.

3. Manpower & Team Management

• Lead, develop, and mentor a team of Supervisors, Line Leaders, Operators, and Helpers.

• Plan daily manpower allocation across lines ensuring optimal productivity and skill balance.

• Conduct skill assessments, on-the-job training, and performance evaluations.

• Build a culture of teamwork, discipline, and accountability.

4. Material & Inventory Coordination

• Ensure timely availability of frames, fabrics, foam, accessories, and other BOM components.

• Coordinate with SCM and stores to avoid shortages and overstocking. • Ensure proper material traceability and adherence to FIFO norms.

• Highlight BOM non-adherence or material-related quality concerns.

5. Equipment, Maintenance & Safety

• Ensure all conveyor lines, tools, machines, and fixtures function with minimal downtime.

• Collaborate with the maintenance team for preventive and breakdown maintenance.

• Enforce strict safety protocols, PPE usage, and safe work practices.

• Uphold 5S standards across all production areas.

6. Reporting & Documentation

• Review and approve daily production reports, downtime logs, rejection reports, and shift summaries.

• Present MIS dashboards such as productivity, OEE, manpower efficiency, and quality metrics.

• Ensure accurate ERP/production data entry by team members. 7. Continuous Improvement

• Drive Kaizens, TPM, Lean, and other improvement projects to improve productivity and reduce waste.

• Lead initiatives for cycle-time reduction, ergonomic enhancement, and layout optimization.

• Support digital transformation initiatives in production tracking and automation.

Key Performance Indicators (KPIs)

• Production Achievement vs Target

• OEE / Line Efficiency

• First Time Right (FTR) & Quality Rejection Rate

• Productivity (Units per Man per Shift)

• Material Utilization & BOM Adherence

• Downtime Reduction

• 5S & Safety Compliance Score Skills & Attributes

• Strong leadership and people management skills

• Excellent understanding of sofa manufacturing processes

• Knowledge of Lean, Kaizen, TPM, and other improvement methodologies

• Problem-solving and decision-making capability under pressure

• Good communication, analytical, and coordination skills

• ERP & Microsoft Excel proficiency

Education & Experience

• Bachelors degree in Mechanical/Production/Industrial Engineering (preferred)

• 6-12 years of experience in manufacturing, including at least 35 years in a supervisory/managerial role