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