Production Manager – Wiring Harness Manufacturing

  • 8-10 Years
  • ₹ 6-10 LPA
  • Changodar, Ahmedabad, Gujarat
  • On-site
  • Full-time
Wiring Harness Manufacturing Production Management Production Planning & Control PPC ERP Systems Lean Manufacturing Continuous Improvement Shop Floor Management Manpower Planning KPI Monitoring Quality Control ISO 9001:2015 IATF 16949:2016 IPC/WHMA-A-620 Inventory Management JIT Preventive Maintenance Cost Control Production Budgeting New Product Development

About the Role

Celestix Industries is looking for a hands-on Production Manager to lead our wiring harness manufacturing and cable assembly production operations.

This is not a desk-only production planning position.

The candidate should understand the actual manufacturing process and be capable of managing production from raw wire and components through cutting, stripping, crimping, splicing, assembly, testing, inspection and final dispatch.

We are looking for someone who can combine strong shop floor management, production planning, manpower planning, quality control, lean manufacturing and continuous improvement to achieve production targets and ensure on-time customer delivery.

The ideal candidate will have previous experience in:

  • Wiring harness manufacturing
  • Cable assembly
  • Automotive electrical components
  • Electrical assembly
  • Wire processing
  • Similar high-volume assembly manufacturing

Products You May Work On

Production may include:

  • Automotive wiring harnesses
  • Industrial wiring harnesses
  • Appliance wiring harnesses
  • Power cables
  • Battery cable assemblies
  • Molded cable assemblies
  • Braided cable assemblies
  • Electrical cable assemblies
  • Custom OEM harnesses
  • High-current cable assemblies

Key Responsibilities

1. Production Planning & Execution

  • Prepare daily, weekly and monthly production plans based on customer requirements.
  • Convert customer demand and open orders into realistic production schedules.
  • Allocate manpower, machines and material based on production priorities.
  • Ensure production targets are achieved on time.
  • Monitor production plan versus actual output.
  • Identify shortages or bottlenecks before they affect customer delivery.
  • Coordinate urgent customer requirements and priority production.
  • Maintain accurate visibility of WIP at each manufacturing stage.

This requires strong production planning, production scheduling, resource allocation and production control to maintain output and meet customer delivery commitments.

2. Wiring Harness Manufacturing Operations

The Production Manager should understand the complete wiring harness manufacturing flow, including:

  • Wire cutting
  • Wire stripping
  • Crimping
  • Terminal insertion
  • Connector assembly
  • Twisting
  • Soldering
  • Splicing
  • Ultrasonic welding
  • Harness routing
  • Taping
  • Braiding or sleeving
  • Loom assembly
  • Labeling
  • Continuity testing
  • Electrical testing
  • Visual inspection
  • Final packing

Hands-on knowledge of several of these processes is expected.

The role requires practical understanding of wire harness assembly, electrical harness manufacturing, production operations and harness testing.

3. Crimping & Wire Processing

Strong knowledge of wire processing is particularly valuable.

The candidate should understand:

  • Wire specifications
  • Cutting lengths
  • Strip lengths
  • Terminal selection
  • Crimping parameters
  • Applicators
  • Crimp height
  • Pull-force requirements
  • Conductor crimp
  • Insulation crimp
  • Terminal deformation
  • Wire damage
  • Crimp defects
  • Process setup

The Production Manager should be able to identify when a crimping process is not producing acceptable results and coordinate corrective action quickly.

4. Production Planning & Control (PPC)

The role will work closely with PPC, Procurement, Stores and Planning.

Responsibilities include:

  • Production capacity planning
  • Line loading
  • Material readiness
  • WIP control
  • Manpower planning
  • Machine loading
  • Dispatch prioritization
  • Production backlog monitoring
  • Daily production reviews
  • Delivery-risk escalation

The objective is simple:

Production problems should be identified before they become delivery problems.

Effective production planning and control, capacity planning, material coordination and production scheduling are essential for ensuring that production runs according to customer requirements.

5. Manpower Planning & Shop Floor Management

Lead and develop a manufacturing team including:

  • Production Engineers
  • Supervisors
  • Line Leaders
  • Operators
  • Technicians
  • Helpers

Responsibilities include:

  • Daily manpower allocation
  • Skill-matrix management
  • Operator training
  • Productivity monitoring
  • Attendance and absenteeism coordination
  • Shift planning
  • Performance management
  • Shop-floor discipline
  • Escalation of manpower shortages

The candidate must be comfortable spending significant time on the production floor.

Strong manpower planning, workforce management, operator allocation, shift planning and shop floor management skills are important for maintaining consistent production performance.

6. Productivity Improvement & Line Balancing

Continuously improve manufacturing output through:

  • Line balancing
  • Workstation optimization
  • Cycle-time reduction
  • Takt-time analysis
  • Bottleneck removal
  • Layout improvement
  • Better operator utilization
  • Jig and fixture development
  • Automation
  • Work-content balancing
  • Standardized work

Track output in measurable terms rather than only relying on general observations.

The Production Manager should actively drive productivity improvement, manufacturing efficiency, line balancing and cycle-time reduction to improve shop-floor performance.

7. Quality Control & Process Discipline

Work closely with Quality to maintain strong process discipline.

The candidate should understand:

  • IPC/WHMA-A-620 requirements
  • In-process inspection
  • Crimp quality
  • Pull-force testing
  • Crimp-height verification
  • Continuity testing
  • Electrical testing
  • Visual workmanship requirements
  • Traceability
  • Non-conformance handling
  • Root cause analysis
  • Corrective action

Support implementation of:

  • PFMEA
  • Control Plans
  • Work Instructions
  • Process audits
  • CAPA
  • Customer corrective actions

The role requires practical understanding of quality control, production quality and manufacturing process control to maintain consistent wiring harness quality.

8. Rejection & Rework Reduction

The Production Manager will actively monitor:

  • Internal rejection
  • Rework
  • Scrap
  • Customer complaints
  • First-pass yield
  • Process defects

Typical defects may include:

  • Incorrect wire length
  • Incorrect strip length
  • Poor crimp
  • Terminal back-out
  • Incorrect connector
  • Missing component
  • Wrong routing
  • Wrong label
  • Continuity failure
  • Incorrect wire color
  • Damaged wire
  • Poor soldering or splice quality

Corrective actions should address root causes rather than repeatedly sorting defective product.

Reducing rework, rejection and scrap is an important part of continuous improvement, production productivity and manufacturing cost control.

9. Material Planning & Inventory Coordination

Work closely with Purchase and Stores to ensure material availability.

Monitor:

  • Wire
  • Cable
  • Terminals
  • Connectors
  • Seals
  • Sleeves
  • Tubing
  • Tape
  • Labels
  • Clips
  • Fasteners
  • Packaging

Prevent production loss caused by missing materials through effective planning and escalation.

The Production Manager should coordinate material planning, shortage management and material availability to support uninterrupted wiring harness manufacturing operations.

10. Equipment & Machine Utilization

Monitor production equipment including, where applicable:

  • Automatic wire cutting and stripping machines
  • Crimping machines
  • Applicators
  • Pneumatic presses
  • Ultrasonic welding machines
  • Twisting machines
  • Soldering equipment
  • Continuity testers
  • Electrical testers
  • Pull-force testers
  • Crimp-height measuring equipment

Coordinate with Maintenance to reduce downtime and improve equipment availability.

Strong focus on machine utilization, equipment availability, downtime reduction and capacity utilization is required to maintain manufacturing productivity.

11. Lean Manufacturing & Continuous Improvement

Drive practical improvement activities including:

  • Kaizen
  • 5S
  • Visual management
  • Standard work
  • Lean manufacturing
  • Waste elimination
  • Process flow improvement
  • Layout improvement
  • Poka-yoke
  • Cycle-time improvement
  • Changeover reduction

We are looking for someone who actively improves processes rather than simply maintaining the existing system.

The candidate should be able to apply lean manufacturing, Kaizen, 5S, waste reduction and continuous improvement principles in a practical production environment.

12. Production KPIs & Performance Monitoring

The Production Manager should regularly track and review metrics including:

  • Plan vs actual production
  • Productivity
  • Output per operator
  • Efficiency
  • First-pass yield
  • Rejection percentage
  • Rework percentage
  • Scrap
  • Overtime
  • Absenteeism
  • Machine downtime
  • WIP
  • Customer delivery
  • OTIF / On-Time Delivery
  • Capacity utilization

Management should be able to understand the health of production from measurable data.

Accurate tracking of production KPIs, manufacturing productivity, machine utilization, production efficiency and on-time delivery is essential.

13. Production Cost Control

Identify and execute improvements that reduce manufacturing cost without reducing quality.

Focus areas may include:

  • Manpower productivity
  • Material utilization
  • Scrap reduction
  • Rework reduction
  • Overtime
  • Cycle time
  • Machine utilization
  • Tooling
  • Consumables
  • Process automation

The role requires a continuous focus on production cost control, cost reduction and manufacturing efficiency while maintaining customer quality and delivery requirements.

14. New Product Introduction (NPI)

Support Engineering and NPD with new customer programs.

Responsibilities may include:

  • Manufacturing feasibility
  • Production layout
  • Process flow
  • Tooling requirements
  • Fixture requirements
  • Capacity
  • Manpower
  • Trial production
  • Pilot lots
  • Ramp-up
  • Process validation

Ensure new products transition smoothly into regular production.

15. Customer & Audit Support

Support:

  • Customer audits
  • ISO audits
  • IATF audits
  • Process audits
  • Customer visits

The candidate should be comfortable explaining production controls, process capability and corrective actions to customers and auditors.

Required Experience

We prefer candidates with 6–12 years of manufacturing experience, including meaningful responsibility for production teams.

Direct wiring harness experience is strongly preferred.

Relevant backgrounds include:

  • Wiring harnesses
  • Cable assemblies
  • Automotive electrical components
  • Electrical/electronic assembly
  • Switchgear assembly
  • Electrical connectors
  • Wire and cable processing

Candidates with practical experience in production management, production planning, manpower management, shop floor operations and lean manufacturing will be particularly relevant.

Candidate Backgrounds We Will Consider

We should not unnecessarily restrict the search only to someone whose current title is "Production Manager."

Candidates currently working as:

  • Production Manager
  • Assistant Production Manager
  • Deputy Manager – Production
  • Senior Production Engineer
  • Production In-Charge
  • Manufacturing Manager
  • Production Supervisor
  • Section Head
  • Manufacturing Engineer

may apply if they have managed meaningful production responsibility.

Qualification

Diploma / B.E. / B.Tech in:

  • Electrical Engineering
  • Electronics Engineering
  • Mechanical Engineering
  • Production Engineering
  • Industrial Engineering
  • Automobile Engineering

Relevant wiring-harness production experience will receive greater weight than the exact engineering discipline.

Preferred Technical Knowledge

Experience with the following is valuable:

  • IPC/WHMA-A-620
  • ISO 9001
  • IATF 16949
  • PFMEA
  • Control Plan
  • Lean Manufacturing
  • 5S
  • Kaizen
  • ERP / MRP
  • Excel
  • Production planning systems

Additional relevant competencies include production scheduling, production control, capacity planning, line balancing, material planning, manpower planning, machine utilization, quality control and continuous improvement.

Ideal Candidate

A strong candidate should be able to walk onto a wiring harness production floor and quickly answer questions such as:

  • Why is today's output below plan?
  • Where is the bottleneck?
  • Is manpower properly balanced?
  • Which material shortage could affect tomorrow's production?
  • Why is crimp rejection increasing?
  • Why is WIP accumulating at one operation?
  • Which machines are underutilized?
  • Can the line meet next month's increased demand?
  • Where can cycle time be reduced?
  • Which issue requires immediate escalation?

We are looking for someone who takes ownership of production results rather than simply reporting them.

The ideal Production Manager understands the relationship between production planning, manpower allocation, material availability, shop-floor execution, quality, productivity and on-time delivery.

What Success Looks Like

Success in this role means:

  • Production targets are consistently achieved.
  • Customer deliveries are protected.
  • Material shortages are identified early.
  • Rejection and rework decrease.
  • Productivity improves.
  • Operators are properly trained.
  • Machines and manpower are effectively utilized.
  • Production problems are escalated early.
  • New products launch smoothly.
  • Production data is accurate and actionable.
  • The shop floor operates with strong discipline and ownership.

We are looking for a Production Manager who combines hands-on wiring harness manufacturing experience with strong production planning, shop floor management, manpower planning, lean manufacturing, and continuous improvement capabilities.

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