Team Leader - COE

Drive manufacturing excellence initiatives to increase throughput of manufacturing sites by periodical interactions and involvements at functional areas and hence provide a support platform of operational efficiency to achieve quality standards and production targets

Monitor sustainability of performance dialogue in section/ department to check plan vs. actual production and find root cause if there is any delay

• Monitor Shift PD and Section PD to check sustainability of review mechanism
• Monitor daily department head PD and update the action items generated during discussion
• Track action items and review open items on daily basis with the concerned person
• Conduct production review meet monthly with unit head vs. department head to review all production KPIs
• Monitor PDCA (Plan do check and act) system continuously
• Ensure maximum utilization of machine in working shift by reviewing the under-utilization of the machine and mentioning the same while tracking action item
• Focus on reduction of waste, variability and inflexibility of 3M (Man, material, method) to increase value added portion of work, efficiency of people, profitability and customer satisfaction respectively
• Provide support to department for audit readiness by being compliant

Monitor OEE (Overall Equipment Effectiveness) and efficiency of area/ machine and identify major loss to focus on continue improvement

• Monitor Daily OEE of bottleneck machine to measure the losses during process
• Review monthly the OEE data of all machine and area and ensure to minimize the major loss (Speed loss/ breakdown loss/ unplanned loss/ planned loss/ changeover loss)
• Reduce the cost, effort, and frustration required to perform the procedure or changeover by streamlined procedures provide to many related areas of the production
• Track monthly changeover time of machine/ area to maintain/ sustain compared to standard time
• Monitor the existing process of production and analyse the relevant data to standardized process cycle time
• Prepare and monitor value stream mapping of runner products
• Conduct Hourly planning of bottleneck machine to reduce down time loss
• Conduct time and motion study of man/ material to optimize the productivity time and simplify the process
• Conduct DILO Analysis to increase the personal efficiency (OPE)
• Maintain the efficiency benchmark of each machine/ area by tracking and reviewing machine/ area monthly

Monitor CapEx and OpEx and create awareness about frugality to ensure cost reduction

• Review monthly the operating and manpower expenses and compare expenses with historic data
• Conduct frugality workshop session on cost saving to create awareness among the people for frugal mind set
• Distribute pool manpower from non-working area to working area to reduce associates cost

Conduct Kaizen implementation session for continue improvement

• Conduct idea generation and evaluation session frequently w.r.t. to quality/ cost/ productivity/ process/ safety etc.
• Gather the ideas generated from departments and sections and update status
• Implement 5 “S”  framework and check for sustainability in departments
• Identify and propose monthly the person with the best idea to be awarded as the performer of the month
• Conduct cross-functional brain-storming and problem solving session on root causes of variance

Monitor yield of runner products to focus on continue improvements & Sustainability

• Monitor the yield of runner products to ensure yield above the baseline
• Perform rejection analysis and provide support to production team by identifying the source of rejection and providing alternatives to increase the yield of products

Prepare and maintain Dashboard to track sustainability progress

• Prepare daily report of unit by collecting the data from all department
• Prepare weekly updates and share to unit head
• Prepare monthly unit performance report to share with Unit head
• Maintain accountable goal display board to keep functions in track for achieving their goals

Conduct Trainings or Boot camp to create awareness about manufacturing transformation.

• Provide Jaagruti induction training to new joined employees
• Conduct boot camps on Jaagruti tools i.e. Performance dialogue, OEE, SMED and Waste identification & Elimination
• Conduct Awareness session on efficiency and changeover improvement

Sustaining the Jaagruti KPIs which are:

Planning KPIs.:  OTIF, D2D time and Throughput

Production KPIs. : Process cycle time, Changeover time, Yield, OEE, Efficiency and Run rate of production.

Challenge overcome by daily, weekly and monthly monitoring, set benchmark for each KPI, create awareness and continue improvements

• Production for day to day activities like PD (Daily)
• QA for periodic activity idea generation and evaluations (need basis)
• Warehouse for PD, time motion study, material movement day to day activity (daily)
• Engineering for tracking daily breakdown day to day activity (daily)
• HSE for routine safety (need basis)
• HR for HR related ideas, awards need basis

Admin for need basis

• Brain-storming session conducted annually: 12
• Average 100 ideas generated in a year
• PD score should be maintain above 75%
• OTIF should be more than 95%
• D2D time should be below the baseline of each dosage form
• 100% adherence to manufacturing KPIs
• Continue improvement in OEE and to maintain efficiency above 70%
• Sustaining the yield of products above 97.00%

Changeover time of machine maintain with standard defined time

Action items for continuous improvements (Department head, Unit Head)

Idea evaluation (Department head, Unit Head)

Recommendation generated from Yield improvement study (Department head, Unit Head)

Graduate in Chemical Engineering

3-5 years of industrial engineer              

• Knowledge of Lean manufacturing
• Knowledge of Kaizen principle and Its implementation

Knowledge about computer (Excel, ppt and Word file).