Department: Operational Excellence

Location: Corporate Office Bangalore

About the Role:

We are seeking an experienced and strategic Operational Excellence leader to drive enterprise-wide manufacturing transformation through the implementation and continuous evolution of the Production System (APS). This role will lead Lean transformation initiatives, standardize operational excellence practices across manufacturing locations, improve manufacturing performance, and build a culture of continuous improvement.

The incumbent will partner with plant leadership and cross-functional teams to deliver sustainable improvements in Safety, Quality, Delivery, Cost, Productivity, and Employee Engagement while developing world-class manufacturing capabilities across the organization.

Key Responsibilities:

1. Production System (APS) Deployment:

- Develop, implement, and continuously enhance the Production System (APS) framework across all manufacturing facilities.

- Define the APS roadmap, implementation strategy, governance structure, and maturity assessment model.

- Establish standardized operating practices and ensure consistent deployment of APS principles across all manufacturing locations.

- Drive horizontal deployment of successful improvement initiatives and best practices across plants.

- Monitor APS implementation progress through regular governance reviews and leadership updates.

2. Operational Excellence Projects:

- Conduct structured problem-solving training using Six Sigma methodology for manufacturing teams.

- Lead high-impact cross-functional improvement projects using structured problem-solving methodologies.

- Drive projects focused on:

1. Productivity improvement

2. Quality enhancement

3. Scrap and waste reduction

4. OEE improvement

5. Cycle time reduction

- Ensure projects are completed within defined timelines while delivering measurable financial and operational benefits.

3. Lean Manufacturing, TPM & Shopfloor Transformation:

- Design and implement Lean manufacturing systems to enhance shopfloor efficiency.

- Lead initiatives including:

1. 5S Workplace Organization

2. TPM

3. Visual Factory

4. Standard Work

5. Material Flow Optimization

6. SMED

7. Value Stream Mapping (VSM)

- Promote a culture of disciplined execution and continuous improvement across manufacturing operations.

4. Performance Management & Digital Transformation:

- Develop Operational Excellence dashboards to monitor plant performance and improvement initiatives.

- Drive factory digitization by leveraging digital tools for data collection, visualization, and decision-making.

- Present performance reviews and improvement roadmaps to senior leadership.

5. Capability Building & Leadership Development:

- Build organizational capability by coaching and mentoring manufacturing teams on Lean and Continuous Improvement methodologies.

- Design and conduct training programs on:

1. Lean Manufacturing

2. Six Sigma

3. TPS/TPM

4. Problem Solving

5. Operational Excellence Tools

- Develop competency matrices, identify capability gaps, and establish structured learning roadmaps.

- Foster a culture of ownership, accountability, innovation, and continuous improvement throughout the organization.

6. Stakeholder Collaboration & Governance:

- Partner with Plant Heads, Manufacturing, Quality, Engineering, Supply Chain, Maintenance, and Corporate Functions to drive transformation initiatives.

- Facilitate regular governance meetings to review project progress, remove execution barriers, and ensure alignment with business objectives.

- Support annual operational planning, resource allocation, and budgeting for manufacturing improvement programs.

- Communicate project outcomes, best practices, and strategic recommendations to executive leadership.

Desired Competencies:

Technical Competencies:

- Lean Manufacturing

- Toyota Production System (TPS)

- Total Productive Maintenance (TPM)

- Six Sigma Black Belt

- DMAIC Methodology

- Statistical Process Control (SPC)

- Root Cause Analysis

- Value Stream Mapping

- OEE Improvement

- Kaizen

- Poka-Yoke

- Visual Management

- FMEA

- Operational Excellence Frameworks

Leadership Competencies:

- Strategic Thinking

- Project & Program Management

- Stakeholder Management

- Coaching & Mentoring

- Decision Making

- Influencing Skills

- Presentation & Communication

- Results Orientation

Qualifications:

- Bachelor's Degree in Mechanical, Production, Industrial, Manufacturing, Plastics, or a related Engineering discipline (BE/B.Tech).

- Postgraduate qualification (MBA/PGDM/Operations Management) preferred.

- Certified Six Sigma Black Belt (Mandatory).

- Lean Manufacturing or TPM certifications will be an added advantage.

Experience:

- Minimum 10 - 15 years of progressive experience in Manufacturing, Operational Excellence, Continuous Improvement, Quality, or Industrial Engineering.

- Proven experience driving transformation initiatives across multiple manufacturing locations.

- Demonstrated success in implementing TPM, Lean Manufacturing, and Six Sigma programs.

- Strong track record of delivering measurable business improvements in productivity, quality, cost, and operational efficiency.

- Experience working in high-volume manufacturing environments such as Packaging, FMCG, Automotive, Plastics, Engineering, Chemicals, or Process Industries is preferred.

Key Performance Indicators (KPIs):

- APS Maturity Improvement & Certifications

- Productivity Improvement (%)

- Digitization

- Quality Improvement (PPM/Defects)

- Waste & Scrap Reduction

- Training & Capability Development Metrics

- SPQCDSM Performance Improvement