Project & Operations Manager – Foam & Fabric Lamination
UM Orthotics Pvt. Ltd. • Ludhiana
Project & Operations Manager – Foam & Fabric Lamination About the Company U M Orthotics Pvt. Ltd. is a leading manufacturer of orthopaedic support products, focused on quality and innovative solutions. About the Role We are looking for a Project & Operations Manager to establish and lead the Foam & Fabric Lamination Division from feasibility and plant setup through commercial production. The role will manage process development, machinery, production, costing, quality, productivity and operations. Key Responsibilities * Feasibility & Planning: Conduct techno-commercial feasibility covering demand, capacity, investment, operating cost, ROI and breakeven. Prepare project reports and recommend in-house vs. outsourcing. * Plant Setup: Develop plant layout, production flow and machinery specifications. Lead installation, commissioning and production readiness. Plan power, compressed air, steam, ventilation, adhesive handling and safety systems. * Process Development: Develop foam and fabric lamination processes using heat, flame, water-based, solvent-based and hot-melt technologies. Optimise bond strength, thickness, uniformity, stretchability and durability. * Costing: Develop product costing covering foam, fabric, adhesive, labour, power, machine cost, wastage, rework, packaging, freight and overheads. Maintain standard costs and drive cost reduction. * Vendor Development: Develop suppliers for foam, fabrics, adhesives, release papers, chemicals and packaging. Manage pricing, MOQ, lead time and quality. * Production: Plan production against demand, materials and capacity. Monitor output, downtime, machine efficiency, OEE, wastage and labour productivity. Drive Lean, Kaizen and 5S. * Quality: Establish standards for bond/peel strength, adhesion, thickness, density, surface finish, stretch recovery and delamination resistance. Implement incoming, in-process and final inspection. * Team & Coordination: Recruit and develop supervisors, operators, helpers and maintenance staff. Establish SOPs and work instructions. Coordinate with Purchase, PPC, Quality, R&D, Sales, Finance and Stores. * Safety: Ensure factory, fire, chemical handling, PPE and environmental compliance. Requirements * B.E./B.Tech in Mechanical, Textile, Polymer, Production or Industrial Engineering. Diploma holders with extensive relevant experience may be considered. * 10–15 years of experience in foam/fabric lamination; plant setup and commissioning experience preferred. * Experience in technical textiles, footwear, automotive interiors, mattresses, sportswear, medical textiles or orthopaedic products is an advantage. * Strong knowledge of lamination, adhesive technologies, production costing, vendor development, process optimisation, quality systems and Lean manufacturing. * Strong leadership, project management, negotiation, analytical and problem-solving skills. Key Deliverables Plant commissioned within approved timeline and budget; stable commercial production; standard costing; optimum machine utilisation; controlled wastage; high first-pass quality; qualified vendor base; complete SOP/process documentation; continuous productivity and cost improvement. Location of work : Ludhiana , Punjab
