Executive - Manufacturing

Job Title: Executive – Manufacturing (Maintenance) Location: Madurai Role Purpose: To support the Twisting Manager in overseeing daily maintenance operations, ensuring safe, efficient, and cost ‑ effective production that meets quality standards. The role is responsible for monitoring key process parameters, managing twisting machinery maintenance and resources, and driving continuous improvements in productivity, quality, and compliance while adhering to Coats’ global standards. Principal Accountabilities: Safety – No.1 Priority SHE compliance – Strict adherence to safety protocols and audits. Ergonomics improvement – Kaizen for safer operator handling. 5S implementation – Sort, Set in Order, Shine, Standardize, Sustain in maintenance/service areas. Core – Maintenance Planned maintenance – Maintain History Cards for each machine with schedules, spares, and service records. Preventive maintenance – Update History Cards for schedules and ensure recurring issues are eliminated. Breakdown maintenance – Record breakdowns in History Cards, find root causes, and implement corrective actions. Idle spindle monitoring – Track idle spindles in SEW and TFO to improve efficiency % and reduce kWh/kg. Air leakage monitoring – Periodically check CFM consumption in SEW for better compressor utilization. Energy optimization – Monitor motor loads and reduce energy per kg. Spare parts planning – Ensure availability of critical spares; follow LRE well in advance. OEM spares usage – Use OEM spares only in critical processes such as SEW. GAMMA application follow‑up – Record all maintenance activities in GAMMA software, track breakdowns, and derive spares cost. STSP monitoring – Prepare monthly reports on stores and spares consumption for budget control. TPM practices – Apply Autonomous Maintenance, Planned Maintenance, and Focused Improvement. Productivity Improvement Kaizen projects – Simplify operations, improve ergonomics, safety, and quality. Lean Six Sigma – Drive productivity and waste reduction. Employee engagement – Train and guide operators to enhance machine performance. Quality Lot pass % – Ensure FTK/Quantum requirements are met. SOPs & standards – Implement work instructions and best practices. Kaizen in quality – Continuous improvement for defect reduction. Cross-functional communication – Work with QA, Production, HR for quality alignment. Production Process monitoring – Ensure SSP, cotton, core, specialty yarn parameters are stable. Operational metrics – Track utilization, OEE, energy per kg, idle times. Automation support – Drive automation in material movement. Shift reporting – Report downtime, deviations, and performance. Education, Qualifications and Experience : Graduate in Textile Technology or related field. 5–7 years of Strong technical knowledge and experience in twisting/spinning maintenance activity. Hands-on exposure in machinery…