Sr. Lead Manufacturing

Location: Lahore

Company: Zyp

Salary: Rs. 6-7 lakh / month

Equity: Significant shares in the company

Reports to: Head of Manufacturing & Design

 

About Us:

Zyp is an innovative electric mobility startup, dedicated to revolutionizing transportation by manufacturing cutting-edge electric motorcycles, advanced battery packs, and intelligent battery swap stations. We are committed to delivering efficient and sustainable mobility solutions while optimizing every facet of production.

 

Job Overview:

The Sr. Lead Manufacturing will play a pivotal leadership role in managing and optimizing the manufacturing processes at the company. This role will focus on the efficient production of electric motorcycles, battery packs, and battery swap stations through the application of Lean Manufacturing principles. The ideal candidate will have a deep understanding of the automotive sector, strong knowledge of automotive design and manufacturing tools, and experience in scaling manufacturing operations. This person will lead efforts to ensure production is timely, efficient, cost-effective, and high quality.

Key Responsibilities:

• Lead and oversee the full-scale production of electric motorcycles, battery packs, and battery swap stations.
• Apply extensive knowledge of the automotive industry to implement cutting-edge manufacturing practices and technologies.
• Foster a culture of accountability, respect and professional excellence within the manufacturing organization
• Utilize and optimize automotive design and manufacturing tools, such as CAD, CAM, and PLM software, to streamline processes.
• Implement and continuously improve Lean Manufacturing processes to optimize production efficiency, reduce waste, and enhance quality.
• Manage day-to-day manufacturing operations, including planning, budgeting, scheduling, and team supervision.
• Develop and execute strategies to meet production goals, timelines, and cost targets while maintaining product quality standards.
• Collaborate closely with R&D, supply chain, and design teams to ensure seamless integration of new products into the manufacturing process.
• Drive continuous improvement initiatives across all production areas, utilizing best practices in automation, lean production techniques, and innovation.
• Ensure adherence to all safety, environmental, and regulatory standards in the manufacturing facilities.
• Build and mentor a high-performing manufacturing team to support growth and scalability.
• Intimate production plan to vendor and supplier to ensure timely delivery of materials and components.
• Monitor production KPIs and report on progress to executive leadership.
• Manage capital equipment investments and facilities maintenance to ensure optimal operational capacity.

Key Qualifications:

• Bachelor’s degree in Mechanical Engineering, Industrial Engineering, or a related field (Master’s degree is a plus).
• 7+ years of experience in a senior manufacturing role, with a strong background in the automotive sector.
• Extensive knowledge of automotive design and manufacturing tools (e.g., CAD, CAM, PLM software).
• Strong experience with Lean Manufacturing, Six Sigma, or other process improvement methodologies.
• Proven track record of scaling manufacturing operations in a fast-paced startup or growth environment.
• Excellent leadership skills, with a focus on building high performing teams within a collaborative, accountable and respectful team culture.
• Strong analytical, problem-solving, and project management abilities.
• Experience with manufacturing automation and technology integration is a plus.

What We Offer:

• Competitive salary and benefits package.
• Ownership via equity shares in the company
• Opportunity to lead and shape the manufacturing function of a rapidly growing electric mobility company.
• A collaborative and dynamic work environment focused on innovation and sustainability.

 

Top Success Metrics for this Role:

• On-time Delivery: Are customer orders being delivered on time as committed?
• Cost of Poor Quality (COPQ): Total costs related to quality including prevention costs, assessment costs and failure costs. Lowering COPQ reflects strong leadership in continuous improvement
• Unit Cost Reduction: How much does it cost to produce a unit (Direct labor cost + direct material cost + overhead costs) and how is this reduced through diligent planning and continuous action?
• Inventory Turns: How efficiently is production running to meet customer demand while minimizing inventories?
• Kaizen (Continuous Improvement) Events initiated: Number of manufacturing improvement initiatives that are initiated under his/her leadership
• 360 Feedback Score: People reporting to the Lead and peers provide a high 360 degree feedback score in anonymous surveys

 

Additional Success Metrics for this Role

• Defects per Unit (DPU): On timely deliveries and on average how many defects per unit were found. Ideally zero but trending DPUs trending downwards towards 0 defects will show effective leadership
• First Pass Yield (FPY): Percentage of products that pass inspection without needing rework.
• Total number of Defects: Quarterly and overall average number of defects seen in units in customer’s hands e.g. 100 bikes produced, 200 defects seen brings average to 2 per unit in a given time frame.

 

Employee Value Proposition (EVP):

This role offers the unique opportunity to lead and shape the manufacturing operations of a cutting-edge electric mobility company, driving innovation in the production of electric motorcycles, battery packs, and battery swap stations. You will have a direct impact on revolutionizing sustainable transportation, while also growing your leadership experience in a dynamic, fast-paced environment. The company’s focus on efficiency, sustainability, and quality will allow you to implement industry-leading practices, develop a high-performing team, and make a tangible difference in the electric mobility space.

 

Key Performance Objectives (KPIs):

Within the first 30 days, you will implement a systematic approach to measure the Cost of Poor Quality (COPQ) and create a detailed action plan to cut this cost by 50% within the following 90 days. Success in this objective will be evaluated by the COPQ reduction figures, and these will be measured monthly.

By the end of your first 60 days, you will have designed and deployed a Just-in-Time (JIT) inventory management system. This will significantly optimize inventory levels and reduce excess stock, directly improving production efficiency. The effectiveness of the JIT system will be measured by a reduction in inventory holding costs and increased material flow efficiency, which will be reviewed quarterly.

Within the first 90 days, you will create a plan to reduce the unit cost of production by 30% and successfully execute this plan over the following three months. This KPI will be measured through regular cost audits and tracked monthly for effectiveness.

 

At the six-month mark, you will implement a monthly Kaizen improvement dashboard that tracks and communicates continuous improvement progress. A tangible deliverable will be the increase in production efficiency metrics by at least 20% compared to initial measurements.

 

Additionally, within the first six months, you will aim to achieve an 85% employee satisfaction score, as measured by anonymous 360-degree feedback surveys. Building a culture of accountability and respect will be a key factor in achieving this goal, and continuous team development will be emphasized.

 

Challenges:

In achieving these KPIs, you will face several significant challenges. First, managing the reduction of unit costs while maintaining quality will require balancing tight deadlines, supplier coordination, and lean manufacturing practices.

Implementing JIT inventory will necessitate overcoming supply chain variability, requiring close collaboration with vendors to ensure timely deliveries. Additionally, reducing the Cost of Poor Quality by 50% will demand deep process optimization and a cultural shift towards quality control throughout the production team.