Lead Operational Excellence Dahanu

A.

• Deliver Continuous Improvement projects through structured analysis and improve plant performance metrics
• Provide support to CI project leaders in creating project plans, analytics, conducting observation studies, develop control plans to ensure on time project delivery.
• Design and implement change management events in line with CI roadmap
• Support in driving the technical and analytical capability building for the plant to achieve operational excellence

B.

Strategic and planning

• Support the Plant OPEX lead in execution of Plant OPEX strategy
• Identify Improvement areas and plan improvement projects and CI initiatives for the plant
• Create an assessment structure to measure the effectiveness of CI initiatives vis-a-vis the envisaged project outcome
• Plan & Align resources (reading modules) for technical trainings and provide support as needed

Functional

Core

• Facilitate cross functional focussed Improvement projects using Lean and Six Sigma complex problem-solving methodology.
• Analyse Continuous Improvement project data using Six Sigma statistical tools and conduct Gemba observation studies for cause validation and improvement actions.
• Facilitate and develop detailed project plans along with project leaders for Lean and Six Sigma improvement projects
• Coordinate and follow up for action plans and ensure on time delivery of CI projects
• Monitor daily project wise actionable/observation studies/trials and the project participation of the stakeholders through various systemic methods
• Monitor and communicate project status periodically to all stakeholders
• Facilitate Small Group Activity (Quality Circle) teams for Problem Solving.
• Facilitate implementation of Kaizen to drive small improvements across the plant
• Facilitate implementation of Best Practice Replication across the plants
• Facilitate implementation of Low-cost Engineering control solutions to sustenance of improvements
• Conduct Value Stream Mapping, Bottleneck Process studies for Improvements
• Lead implementation of Lean Daily Management system and Tier Reviews to drive Autonomous Shopfloor performance improvements across the plant
• Creation of training modules for various CI skill sets (Lean,Six Sigma, Kaizen,TPM)
• Plan and Execute Six Sigma, Lean, Kaizen, TPM trainings.
• Execute and support in imparting Technical Trainings as per training Calendar

Internal process

• Facilitate weekly Project Reviews with Plant Project team, Plant Mfg Head, Plant Head, Plant Opex Lead, OPEX Program Manager and Global OPEX Head
• Facilitate monthly Plant Steering committee reviews
• Escalate delays, challenges and non-compliances in implementing various CI initiatives to Plant Mfg Head, OPEX Program Manager and Plant Head.
• Create CI Projects Dashboard for Review by Plant Head and Top management
• Conduct GEMBA walks with HODs to regularly identify potential areas of improvements and track the implementation of the same.
• Conduct Gemba Kaizen Idea Workshops and Kaizen initiatives across the plant
• Collaborate with all relevant stakeholders in executing, monitoring and tracking of Technical Training

People development

• Train the people across all departments on Gemba Kaizens to develop CI culture.
• Support in design and execution of Quarterly Kaizen Events, yearly Six Sigma Project competitions for employees.

Identify & develop project teams for analytics and sustenance of improvements.

C.

• No. of high impact Continuous Improvement Projects completed vs planned (*provided this is reflected in the respective JD of Plant Head & Function Head)
• No. of Kaizen and Quality Circle Projects Completed vs planned
• No of processes standardized through various CI projects
• No. of People Trained in CI tools and technique, technical skill set against planned
• Compliance to Kaizen Idea Workshops & Events as per Plan
• GEMBA Walks Improvements Planned vs Actuals
• Overall competency enhancement level of associates Planned vs Actual