Job Description :

Key Purpose of the Job (Position Summary) :

- This position is to drive improvement as per lean concepts, enable people to set and achieve challenging SQCDMP goals through TQM and Industrial Engineering. The role incumbent shall also be responsible for layout preparation, manpower planning, capacity calculation and report preparation on establishing lean culture in the plant.

Key Performance Areas :

- Production line efficiency (OE)

- Lead time reduction.

- Capacity utilization.

- Reduction in NVAs.

- % Cost Reduction / Savings

- Manpower Productivity.

- MUDA/MURI reduction.

- Cycle time study.

- Development of layout.

- Set up time reduction.

- TAT time reduction

- Policy Deployment & Plant MIS Maintenance

- Monthly MIS

- Preparation for the Monthly reviews.

Key activities & responsibilities :

Strategic :

- Driving lean manufacturing initiative for plant by identifying projects through VSM (Value Stream Mapping) & other tools like JIT, KANBAN, Lead time reduction, 5s etc.

- Prepare long term plan to inculcate lean culture for manufacturing & non-manufacturing.

- Advise the senior management on budget preparation of manpower and hiring.

- Conduct mapping and recording of processes/ activities, estimating gap analysis using lean tools & basic principles of motion economy.

- Prepare and review training calendar with respective departments.

- Plan and deploy manpower in respective direct & indirect areas based on work content estimation through the implementation of IE tools to meet production demands at optimized costs.

- Plan and finding solution for TAT reduction for inventory management.

Productivity Improvement :

- Work content calculation and suggestion for contract renewal.

- Video analysis for new & existing SKUs in back shifts.

- Drive Set up change reduction projects with Video Analysis, ECRS etc. techniques.

- Drive automation projects to reduce man interference.

- Work on cycle time reduction on bottleneck machines by taking up man machine motion study.

- Use of Time & Motion Study, MODAPTS, Basic MOST- and Mini MOST- for associate output improvement.

- New SKUs introduction & Capacity impact calculations.

Ergonomics :

- Train employees in best practices as per ergonomics.

- Can conduct REBA & RULA study and suggest safe working procedure.

- Rearrange layout for Muri free working.

- Independently work on improvement of layout of plants and offices.

- Suggest team for selection of MHEs as a part of ergonomic issue.

Documentation & Analysis :

- Analyze performance indicators, trends and information from the daily processes and take necessary actions where appropriate.

- Conduct various analysis to ensure NVAs are reduced.

- Conduct the non-achieving parameter analysis and collectively action through DWM process.

- Perform detailed analysis of the reports generated and make recommendations and present it to the top management.

- Prepare plan v/s actual reports for targets achieved for manufacturing KPIs.

- Review and update Visual standards for improvement in work culture.

- Team & Relationship Management

- Organize and develop an environment for shopfloor associates to work according to optimum cycle time for highest output.

- Provide ongoing coaching & guidance to the team members about Lean Management.

- Ensure interplant communication for implementation of best practices in the plant.

- Represent plant team for machine selection and suggestion for layout management.

- Timely update to head for MIS & dashboard reviews.

Education and Experience Required :

- Engineering Graduate

- Preferably Certificate in Lean Expertise, Lean Six sigma (Green Belt) or PMTS Techniques-MOST, MODAPTs, etc

Experience :

- 6 - 10 years experience in Manufacturing or with experience in leading lean initiatives