Operational Excellence Senior Engineer

Role Overview: -

• We are seeking a highly motivated Industrial Engineer to join our Operational Excellence (OPEX) team for our Pipe Manufacturing Division.

• This role will be responsible for driving productivity improvements, cost optimization, process engineering, Lean implementation, and digital transformation across various manufacturing lines.

• The ideal candidate should have hands‑on experience in manufacturing operations along with strong analytical skills and a solid foundation in Industrial Engineering, Lean tools, and Work Study.

Key Responsibilities

• Conduct detailed Time Studies using stopwatch and PMTS (MOST/MTM) to determine Standard Times.

• Establish Standard Operating Cycles, manpower norms, and productivity baselines.

• Apply Method Study to optimize labor, motion, and process flow.

• Perform Line Balancing for extrusion lines, socketing lines, threading stations, packing operations, etc.

• Analyze and minimize non-value-added activities on the shop floor.

• Support capacity planning, manpower modelling, and machine loading plans.

• Implement Lean methodologies such as:

  • 5S, Kaizen, Poka-Yoke, Kanban, Andon, Jidoka, Visual Controls

  • SMED to reduce die/tool changeover time in extrusion

  • Value Stream Mapping (VSM) – Current State & Future State

  • Standard Work creation and audits

• Drive waste reduction projects focusing on defects, waiting, movement, overprocessing, inventory, and overproduction.

• Lead shop-floor improvement activities, conducting Gemba walks, Kaizen blitz, and cross-functional workshops.

• Capture and analyze Overall Equipment Effectiveness (OEE) across production lines.

• Conduct Six Big Losses analysis and identify chronic issues (Breakdown, Speed Loss, Idling, Defects).

• Work closely with Maintenance to minimize breakdowns and micro stoppages.

• Develop daily/weekly/monthly loss reports and implement action plans to reduce performance and quality losses.

• Collaborate with Production & Quality teams to improve dimensional consistency, reduce ovality, thickness variation, and melt defects.

• Conduct trials for new dies, calibrators, and raw material combinations.

• Drive FMEA, identify high-risk processes, and implement CAPA.

• Support process validation, SOP creation, and continuous standardization across shifts.

• Build and maintain dashboards for OEE, downtime, energy consumption, yield, and scrap trends using Excel / Power BI & Python – Program Based Excel Automation.

• Collect, analyze, and interpret production data to identify improvement opportunities.

• Conduct Cost-per-Kg  analysis for products.

• Support initiatives related to:  Material yield improvement, Energy reduction (kWh/ton) , anpower optimization, Changeover time reduction

• Validate and document project benefits in line with OPEX financial goals.

Requirement:

• B.E./B.Tech in Industrial Engineering, Mechanical, Production Engineering (Mandatory)

• Lean Six Sigma Yellow/Green Belt preferred

• Additional coursework in Lean, TPM, or OPEX is an advantage

• 1–2 years in manufacturing, preferably in manufacturing, polymer processing, or continuous production lines

• Experience in Industrial Engineering OR Operational Excellence department is required

• Excel (Advanced), Power BI dashboards, Basic Python/R (optional), AutoCAD for layout design (preferred)

• Time Study (Stopwatch, MOST/MTM), Work Measurement, DILO, VA, NVA Analysis, Workload & manpower modeling, Line balancing (continuous & batch processes), Plant layout improvement and workflow optimization, Ergonomics and workstation design principles.

• 5S implementation & audit readiness, Kaizen / CI project execution, VSM (Value Stream Mapping), SMED for quick changeovers, Kanban & Pull systems, Poka-Yoke design & implementation, Root Cause Analysis (5 Why, Fishbone, Pareto)

Behavioral Competencies

• Strong analytical and problem-solving ability

• Proactive, structured, and detail-oriented approach

• Good communication for cross-functional collaboration

• Ability to lead shop-floor teams and drive change

• Hands-on, shop-floor oriented mindset

• High sense of ownership and accountability