Senior Engineer – Operational Excellence

**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