Senior Manager – Moulding & Tool Maintenance

Position Summary

Provide strategic and operational leadership for a high-technology, high-volume Moulding

operation supporting precision electronic connector manufacturing. Lead a manufacturing

footprint of 50+ injection moulding machines, covering vertical, horizontal, reel-to-reel, and over-

moulding technologies with advanced automation.

Own the end-to-end performance of the Moulding function, including manufacturing operations,

process engineering, automation, capacity planning, productivity, quality, cost, and delivery, while

building and managing a robust external moulding ecosystem through vendor development, job

work, and purchase models.

Develop a high-quality, technically capable, cost-competitive, and scalable moulding vendor

network to support business growth, capacity flexibility, localization, and supply continuity.

Establish strong technical and commercial governance for outsourced moulding, ensuring

consistent quality, competitive total cost, delivery reliability, process capability, and adherence to

global manufacturing standards.

Key Responsibilities

High-Tech Moulding Operations

• Lead a high-volume Moulding shopfloor comprising 50+ injection moulding machines,

covering vertical, horizontal, reel-to-reel, and over-moulding technologies.

• Drive performance across Safety, Quality, Delivery, Cost, OEE, Productivity, Yield, and

Capacity Utilization.

• Optimize moulding processes, cycle times, machine utilization, material consumption,

changeovers, and process stability.

• Drive advanced automation, robotics, vision systems, process monitoring, and digital

manufacturing solutions.

• Establish robust manufacturing standards to ensure consistent and capable processes.

• Moulding Vendor Development \& External Manufacturing

• Develop and maintain a strategic network of capable moulding vendors to support internal

capacity and business growth.

• Identify, evaluate, technically assess, qualify, and develop new moulding vendors based on

technology, capacity, quality systems, process capability, scalability, and cost

competitiveness.

• Develop vendors capable of meeting stringent requirements for precision electronic

connector components.

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• Establish structured vendor capability assessment, qualification, process validation, and

performance-monitoring systems.

• Develop alternate sources and a resilient vendor base to mitigate capacity, quality, and

supply risks.

• Drive continuous improvement of vendor capability through technical support, process

audits, quality improvement initiatives, and performance reviews.

Job Work \& Purchase Model Management

• Develop and implement appropriate job-work and purchase models based on product

characteristics, capacity requirements, cost competitiveness, and strategic sourcing

considerations.

• Evaluate the optimal make-versus-buy / internal-versus-external manufacturing approach

for moulding requirements.

• Establish clear commercial, technical, quality, and delivery expectations for outsourced

moulding.

• Drive cost-effective external manufacturing without compromising product quality, process

capability, IP protection, delivery, or customer requirements.

• Monitor and optimize the overall economics of outsourced moulding, including conversion

cost, material utilization, logistics, tooling utilization, and total landed cost.

• Ensure effective capacity allocation between internal operations and external

manufacturing partners.

Vendor Quality \& Process Capability

• Establish stringent quality and process capability requirements for all moulding vendors.

• Drive First-Time-Right, defect prevention, process capability, yield improvement, and

reduction of customer-related quality issues.

• Conduct regular supplier process audits and capability assessments.

• Ensure effective implementation of PFMEA, Control Plans, SPC, MSA, process validation,

and structured problem-solving at key vendors.

• Lead supplier corrective and preventive actions for quality and delivery issues.

• Establish vendor scorecards covering Quality, Cost, Delivery, Capacity, Responsiveness, and

Continuous Improvement.

Cost Competitiveness

• Drive a cost-efficient moulding ecosystem through competitive sourcing, productivity

improvement, process optimization, automation, and vendor development.

• Benchmark internal and external conversion costs and identify cost-reduction

opportunities.

• Develop competitive commercial models for job work and purchased moulded

components.

• Partner with Procurement and Finance to ensure transparency and competitiveness of

moulding costs.

• Drive annual cost-reduction and productivity initiatives across the internal and external

moulding network.

Capacity \& Business Continuity

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• Develop short-, medium-, and long-term moulding capacity strategies aligned with business

growth and customer demand.

• Balance internal capacity with external vendor capacity to provide flexibility, scalability,

and responsiveness.

• Establish contingency and alternate-source strategies for critical components.

• Ensure vendor capacity readiness for new product launches, volume ramps, and demand

fluctuations.

New Product Introduction \& Industrialization

• Partner with Engineering, NPI, Quality, and Supply Chain teams for successful

industrialization of new moulded connector components.

• Assess manufacturability and external manufacturing feasibility during product

development.

• Lead vendor selection, capability assessment, trials, validation, and production ramp-up for

outsourced moulding.

• Ensure new vendors and processes achieve required quality, capability, cost, and delivery

targets before production release.

Operational Excellence \& Technology

• Drive Lean Manufacturing, TPM, Six Sigma, Kaizen, automation, and digital manufacturing

across internal and external moulding operations.