The role is accountable for productivity improvement, capacity planning, factory and warehouse design, labor optimization, manufacturing excellence, lean transformation, automation, digital manufacturing initiatives, and end-to-end material flow efficiency across Tejas factories and EMS partners.
The position acts as the bridge between SCM, Manufacturing, Quality, Engineering, Program Management, and Digital Transformation teams to ensure scalable, cost-effective, and highly efficient operations capable of supporting rapid business growth and large-scale telecom deployments.
1. Manufacturing Productivity & Operational Excellence
Drive factory productivity improvement programs across assembly, testing, integration, repair, and warehouse operations.
Establish productivity baselines and annual improvement targets.
- Conduct time and motion studies and labor optimization initiatives.
- Implement Lean Manufacturing, Kaizen, Value Stream Mapping, ECRS, and Six Sigma methodologies.
- Lead cost reduction through waste elimination and process simplification.
- Develop standard work instructions and operational best practices.
Key Deliverables
- Productivity Improvement Roadmap
- Labor Productivity Dashboard
- Annual Cost Reduction Plan
- Lean Transformation Program
2. Capacity Planning & Industrialization
- Develop short-term and long-term manufacturing capacity plans.
- Establish factory readiness plans for major customer programs.
- Define manpower, machine, space, and infrastructure requirements.
- Support business growth planning with scalable manufacturing strategies.
- Lead industrialization of new manufacturing lines and technologies.
Key Deliverables
- Capacity Planning Model
- Factory Expansion Plan
- Resource Utilization Dashboard
- Make vs Buy Analysis
- 3. Factory & Warehouse Layout Engineering
- Design and optimize manufacturing and warehouse layouts.
- Improve material flow and minimize handling waste.
- Drive warehouse-to-line-side supply optimization.
- Establish best-in-class storage and inventory movement practices.
- Define future-state smart factory architecture.
Key Deliverables
- Layout Design Standards
- Material Flow Models
- Warehouse Optimization Projects
4. Manufacturing Process Engineering
- Define assembly, integration, testing, packing, and shipment processes.
- Establish standard process times and labor standards.
- Improve First Pass Yield (FPY) and cycle time performance.
- Support Design for Manufacturability (DFM) and Design for Assembly (DFA).
Key Deliverables
- Standard Time Database
- Process Capability Reports
- Assembly Efficiency Improvements
5. Automation & Digital Manufacturing
- Lead automation initiatives across manufacturing and SCM operations.
- Develop automation business cases and ROI calculations.
- Drive implementation of MES, workflow automation, digital work instructions, traceability systems, and AI-enabled analytics.
- Improve visibility across material, labor, machine, and process performance. [Tejas digi...posal 2023 | PowerPoint]
Key Deliverables
- Digital Manufacturing Roadmap
- Automation Business Cases
- OEE and Throughput Monitoring Systems
- Smart Factory Initiatives
6. New Product Introduction (NPI)
- Ensure manufacturing readiness for new products.
- Drive PFMEA, process validation, line balancing, tooling readiness, and production ramp-up.
- Establish scalable manufacturing processes for optical, wireless, routing, and access products.
- Support engineering teams on DFM/DFT reviews.
Key Deliverables
- NPI Readiness Reviews
- Manufacturing Release Approval
- Ramp-Up Productivity Plans
7. Continuous Improvement & Benchmarking
- Build a culture of operational excellence across all SCM functions.
- Facilitate Kaizen programs and employee-led improvement initiatives.
- Benchmark global telecom, electronics, and EMS best practices.
- Drive annual improvement programs linked to strategic SCM goals. [New SCM at...gic Vision | PowerPoint]
Key Deliverables
- Kaizen Pipeline
- Operational Excellence Scorecard
- Best Practice Repository
8. Cross Functional Leadership
Partner closely with:
- Manufacturing Operations
- Procurement & Sourcing
- Planning & Logistics
- Quality
- R&D
- IT & Digital Transformation
- Finance
- EMS Partners
to ensure end-to-end supply chain effectiveness.
Key Performance Indicators (KPIs)
Productivity & Efficiency
- Labor Productivity Improvement (%)
- Direct Labor Cost Reduction
- Assembly Cycle Time Reduction
- Capacity Utilization
Manufacturing Performance
- First Pass Yield (FPY)
- Overall Equipment Effectiveness (OEE)
- Line Balance Efficiency
- Throughput Improvement
SCM Performance
- Material Flow Efficiency
- Warehouse Productivity
- Inventory Handling Cost
- Fulfilment Lead Time Reduction
Continuous Improvement
- Kaizen Savings
- Automation Benefits Realized
- Cost of Poor-Quality Reduction
- Number of Lean Projects Completed
Strategic
- NPI Ramp-Up Success
- Factory Readiness for New Programs
- Capacity Availability vs Demand
- Digitalization Maturity Index
Technical Skills
- Lean Manufacturing
- Six Sigma (Black Belt preferred)
- Value Stream Mapping
- Capacity Planning
- Factory Layout Design
- Plant Simulation
- Digital Manufacturing
- MES Systems
- ERP/SAP
- Automation & Robotics
- OEE Management
- Time & Motion Studies
- PFMEA / Control Plans
- Data Analytics & Power BI
Leadership Competencies
- Strategic Thinking
- Operational Excellence
- Change Leadership
- Data-Driven Decision Making
- Stakeholder Management
- Team Development
- Business Acumen
- Cross Functional Collaboration
- Customer Focus
- Execution Discipline
Success Profile at Tejas
A successful Head of Industrial Engineering at Tejas will build a world-class telecom manufacturing operating system that delivers:
- Best-in-class productivity
- Scalable manufacturing capacity
- Industry-leading traceability
- Lean and automated operations
- Data-driven decision making
- Rapid NPI and customer deployment readiness
- Continuous cost competitiveness
while supporting Tejas' growth in wireless, optical, routing, and large-scale telecom infrastructure programs
- Responsibilities: - Planning and setting up new assembly line, end to end process validation & implementation for new product.
- Product design review and provide feedback on DFM challenges.
- Prepare PFMEA document for SMT process.
- Sound knowledge and experience on SMT processes: -Paste printing, placement, Reflow, AOI, conformal coating, X ray, Depaneling
- Good experience in through hole component processes: -Preforming, Wave soldering, Selective soldering, Radial & Axial component auto insertion, press fitting.
- Exposure to design of Stencil, SMT pallet, Wave pallet, Depanel jig, preforming tool, connector pressing tool.
- PSPHW / Jigs & Fixtures planning & validation for new product
- SMT process Equipment selection, validation, implementation & monitoring the performance
- Focus on Process improvements which results in Production, Quality, Cost, Delivery & Safety [i.e.OEE, UPH & UPPH improvement & other yield improvements]
- New Technology introduction and its tool & equipment evaluation
- Localization of tools, Jigs and Fixtures
- Responsible for defining the E2E PCB level process flow
- NRE Budget estimation and approval
- Strong analytical skill on failure analysis of Process, Part, design & testing
- Process optimization by conducting time study & re-line balancing
- Asset Management
Mandatory skills:
- Worked on Software like Valor, GC-Preview
- Hands on Experience on VSM, Lean tools usage
- Problem solving using DOE methodology
Desired skills:
- Basics on Time study and Method study
- Project Management skill
Education
- B.E./B.Tech in Mechanical, Production, Industrial, Electronics, Manufacturing Engineering
- MBA / Operations Management (Desirable)
Experience
- 15–20+ years of experience in Industrial Engineering, Manufacturing Excellence, Supply Chain Operations, or Factory Management.
- Minimum 5 years leading large manufacturing engineering or industrial engineering teams.
- Experience in electronics, telecom, EMS, networking products, automotive electronics, or high-tech manufacturing preferred.
