About us
Dunlop Foams is a leading supplier of industrial and consumer foam solutions across Australia and New Zealand. We combine advanced technology, quality materials and manufacturing expertise to deliver innovative foam solutions across a diverse range of industries.
Our products are used in bedding, furniture, healthcare, sports, packaging, transport and cleaning, as well as a wide range of custom-made applications.
As part of The Comfort Group, a proud family-owned business with more than 90 years of experience, we continue to invest in our people, products and operations. Our commitment to innovation and quality has helped us build strong, long-standing relationships with retail, commercial and export customers.
At Dunlop Foams, you’ll be joining an established business with a strong reputation, a focus on continuous improvement and a commitment to its people.
About the role
Lead. Improve. Deliver.
We are seeking an experienced Production Manager – Foam Production & Conversion to lead the end-to-end operational performance of our Foam Division at Heathwood. Reporting to the Site Leader – Operations and working closely with the Group Foams Manager, you will lead the foam division from production planning and raw material requirements through to finished product and on-time delivery.
Our Foam Division is a customer-focused, custom manufacturing operation, where product specifications, volumes and priorities can vary. The successful candidate will bring experience in custom, high-mix, make-to-order or customer-driven manufacturing, with the ability to balance customer requirements, capacity, quality, cost and short lead times.
You will lead multiple production work centres and optimise labour, equipment, workflow and capacity to deliver strong outcomes across Safety, Quality, DIFOT, Productivity, Cost and Customer Service.
Key Responsibilities
- Lead the end-to-end foam production and conversion operation, ensuring safe, reliable and efficient performance
- Optimise labour, machinery, equipment and workflow across multiple work centres
- Plan and schedule production to meet customer requirements, including short lead-time and next-day delivery commitments
- Manage production performance against DIFOT, productivity, quality and cost targets
- Maintain strong process control throughout foam manufacturing, including formulations, chemical streams, processing parameters, yields, and physical properties
- Oversee foam conversion activities to ensure product specifications and customer requirements are consistently achieved
- Coordinate production priorities to maximise throughput and minimise downtime, waste and bottlenecks
- Work collaboratively with Planning, Sales, Customer Service, Dispatch, Maintenance, R&D, Technical Services and Material Handling teams
- Monitor production output, yields, scrap, material usage, chemical costs and labour efficiency
- Manage labour costs and overtime against budget and deliver operational cost-saving initiatives
- Ensure plant, machinery and equipment are maintained in a safe, clean and operationally effective condition
- Drive continuous improvement using Lean Manufacturing, Six Sigma and other improvement methodologies
- Support NPD trials, new technologies, capital projects and operational transformation initiatives
- Build a strong culture of safety, quality, accountability and continuous improvement
About you
We are looking for a hands-on, commercially minded manufacturing leader with experience operating in a custom, high-mix, or make-to-order manufacturing environment. You will understand how to keep customers at the centre of operational decision-making without compromising safety, quality, productivity or cost.
You will bring:
- Demonstrated experience managing complex manufacturing operations across multiple work centres
- Experience managing multiple production work centres and coordinated manufacturing flows
- Proven ability to optimise labour, equipment, capacity and workflow to maximise throughput and customer service
- Experience operating within high-service-level, short-lead-time or just-in-time manufacturing environments
- Strong understanding of production planning, scheduling, process control and operational cost management
- Demonstrated success leading manufacturing teams through growth, capacity expansion, transformation or continuous improvement
- Strong analytical and problem-solving skills, with the ability to use production data to identify issues and drive improvement
- Experience with Lean Manufacturing, Six Sigma or other continuous improvement methodologies
- Strong safety, quality and compliance leadership
- Excellent communication, stakeholder management and people leadership skills
- Experience managing diverse teams within a complex industrial relations environment
- A tertiary qualification in Engineering, Manufacturing, Operations Management or a related discipline is preferred
- Strong people leadership, coaching and performance management skills
- A proactive approach to safety, quality, reliability and operational discipline
Experience in foam processing, conversion, fabrication, plastics, textiles, furniture, bedding or engineered products will be highly regarded, particularly where production is driven by individual customer requirements rather than a fixed, repetitive production schedule.
Why Join The Comfort Group?
You’ll join a business with a proud heritage, a strong reputation, and continued investment in its people, products, and manufacturing capabilities.
You will have the opportunity to:
- Lead a critical Industrial manufacturing function
- Influence production strategy, capacity and operational performance
- Work in a genuinely customer-driven manufacturing environment
- Drive measurable improvements across service, productivity, quality and cost
- Develop and lead a capable and engaged operational team
- Lead continuous improvement, capital and transformation initiatives
- Work collaboratively across a broader manufacturing network
If you are an experienced manufacturing leader who enjoys solving complex operational challenges, developing people and delivering continuous improvement, we would like to hear from you.
Submit your application by clicking the "Apply" button now.
We look forward to hearing from you.
