HOD - Design & Costing - Wire & Cable Industry

1. Process Design & Engineering Leadership

•     Establish and own end-to-end process flow designs (drawing, stranding, insulation extrusion, sheathing, armouring, cabling, and assembly operations) for LAN, power, house wire, instrumentation cables and cable assemblies.

•     Define machine-wise process parameters, line speeds, tooling and die specifications for new products and new customer approvals.

•     Approve process route cards, work instructions and standard operating procedures (SOPs) before release to production.

•     Lead process improvement, automation and de-bottlenecking initiatives to enhance throughput, yield and first-pass quality.

•     Review and approve process changes arising from new raw materials, machine upgrades or customer specification changes.

•     Drive New Product Development (NPD) process design from concept/sample stage through to mass production readiness.

2. Costing & Commercial Support

•     Own the standard costing framework (material, conversion, overhead) for all product categories and ensure it is updated in line with input cost movements (copper, aluminium, PVC, XLPE, PE, etc.).

•     Review and approve product costing sheets, BOM-based cost builds and quotations for new enquiries, tenders and key accounts.

•     Provide costing inputs for pricing decisions, margin analysis and profitability reviews in coordination with Sales, Marketing and Finance.

•     Benchmark costs against competitors and industry standards; identify and lead cost-reduction and value-engineering projects.

•     Validate costing impact of engineering changes, alternate raw materials, and process modifications.

3. Cross-Functional Coordination

•     Work closely with Production, Quality, R&D, Procurement, Sales and Finance to ensure process and cost data integrity across the value chain.

•     Coordinate with Procurement on raw material specifications, alternate vendor qualification and cost-saving substitutions.

•     Support Sales/Business Development with technical-commercial inputs for tenders, RFQs and customer negotiations.

•     Liaise with R&D and Quality on new product qualification, testing requirements and regulatory/standard compliance (BIS, IS, IEC, UL, RoHS as applicable).

4. Team Leadership & Governance

•     Lead, mentor and develop the Process Design & Costing team, including Executives and Engineers.

•     Set departmental KPIs/targets, review performance and build technical capability within the team.

•     Establish document control, version management and audit trail for all process design and costing records.

•     Ensure compliance with ISO/quality management system requirements relevant to process and costing documentation.

•     Present periodic reports to senior management on cost trends, margin performance, process efficiency and improvement initiatives.

•     Costing accuracy (variance between estimated vs. actual cost)

•     Process yield improvement and scrap/wastage reduction

•     Turnaround time for new product costing and process design release

•     Cost savings achieved through value engineering / process optimisation

•     On-time NPD process readiness

• •     Team productivity and capability development