Current jobs related to Lead -Material Handling - Hosūr, Tamil Nadu - Stellantis

OBJECTIVE:

• Lead and coordinate all Material Handling and Logistics operations across the plant, covering inbound material receipt, internal storage and movement, and outbound shipments to external and internal customers.
• Ensure smooth, timely, and accurate flow of materials to production through effective application of 3R Principles (Right Part, Right Time, Right Quantity).
• Drive best practices in safety, 5S, lean logistics, cost control, and overall warehouse performance.
• Take end-to-end responsibility for truck management, yard operations, and customs clearance coordination for import/export processes.
• Foster a skilled, motivated, and high-performing team through leadership, coaching, and process ownership

KEY ACCOUNTABILITIES:

Description

• Overall management of warehouse operations, inbound & outbound logistics, and packaging ensuring compliance with safety, quality, and productivity standards.
• Coordinate and oversee timely receipt, storage, handling, and dispatch of materials in line with production requirements and customer commitments.
• Drive continuous improvement programs across warehousing, logistics, and packaging using Lean, Kaizen, and Other Methods
• Manage manpower planning, skill development, and performance management for direct and indirect reports.
• Lead and monitor implementation of FIFO, 5S, TPM, MHE operation standards and safety protocols.
• Maintain inventory accuracy, manage stock control processes including cycle counts, annual stocktaking, and scrap handling.
• Collaborate with procurement, production, quality, and logistics teams for efficient material flow and issue resolution.
• Plan and monitor packaging operations ensuring optimal use of materials and compliance with packaging specifications.
• Manage outbound logistics to meet customer delivery schedules and optimize transportation costs.
• Ensure compliance with environmental regulations and company sustainability initiatives.

TARGETS AND KPIS:

. Safety, Ergonomics & 5S Governance

• Ensure adherence to safety protocols, PPE usage, 5S standards, and environmental regulations across all material handling areas.
• Lead proactive safety audits and ergonomics risk assessments across shifts and departments; initiate systemic corrective actions and track closures.
• Drive a zero-incident culture by identifying unsafe behaviors or conditions, establishing a coaching framework, and leading safety-focused campaigns.

2. People Development & Resource Planning

• Evaluate workforce skills and implement a structured multi-domain upskilling and cross-training plan for blue collars, team leaders, And Shift Leaders.
• Develop and sustain a succession pipeline for critical roles through skill matrix analysis and capability-building workshops.
• Embed SPW and Lean leadership practices in team leaders and shift leaders through coaching, mentoring, and performance dialogues.

3. Logistics & Inventory Accuracy

• Ensure 100% stock location accuracy and inventory integrity across internal warehouses, line-side inventory zones, and external locations.
• Drive alignment with Material Planning to ensure real-time visibility of critical parts, risk mitigation in part shortages, and optimized replenishment cycles.
• Champion PFEP (Plan for Every Part) accuracy, and ensure timely updates reflecting routing, packaging, and material flow changes.
• Implement and monitor robust cycle count, reverse logistics, and annual stock-taking strategies ensuring compliance and audit readiness.

4. Operational Excellence in Inbound & Outbound Logistics

• Lead and standardize inbound and outbound logistics performance, including truck management, yard optimization, dock scheduling efficiency.
• Collaborate with Transport and Packaging teams to ensure on-time material receipt and dispatch, following FIFO and lean material flow principles.

5. Equipment & Infrastructure Optimization

• Oversee equipment health assessments and TPM compliance for all material handling assets (PIVs, MHE, racks, conveyors, dock levelers, AGVs).
• Lead CAPEX justification and ROI evaluation for new equipment investments and automation initiatives (LCA/AGV projects).

6. Process Improvement & Cost Efficiency

• Identify and lead plant-wide transformation projects targeting logistics cost reduction, productivity improvement, and material flow optimization.
• Develop layout and flow enhancements in collaboration with Industrial Engineering, Manufacturing Engineering, and Kaizen teams.
• Standardize and institutionalize lean logistics methodologies (e.g., Kanban, supermarket, MIFA, VSM) across the entire material handling value chain.

Key Performance Metrics:

• Ensure daily fulfillment of production requirements by enabling timely and accurate supply of materials to all feeder shops and assembly zones.
• Lead root cause analysis of daily OPE (Overall Plant Efficiency) losses related to material flow; drive corrective actions and implement sustainable countermeasures across shifts.
• Maintain high standards of inventory location accuracy (target ≥98%) across internal warehouses and line-side storage to ensure real-time material traceability and minimize search losses.
• Oversee synchronized unloading of inbound materials aligned with production demand and just-in-time delivery principles.
• Achieve and sustain ≥99.5% stock accuracy, ensuring alignment between physical and system inventory across all material handling zones.
• Drive deployment of MIFA (Material & Information Flow Analysis) and SPW (Stellantis Production Way) methodologies to optimize internal logistics flows and eliminate non-value-added activities.
• Guarantee strict adherence to safety standards with a zero lost-time incident target; proactively identify and eliminate risks through audits, training, and team engagement.
• Promote and maintain a healthy work environment, ensuring all ergonomic, safety, and well-being KPIs are continuously met for all employees under material handling and warehouse operations.
• Monitor and close any environmental compliance gaps within the warehouse perimeter, in alignment with company and regulatory guidelines.

COMMUNICATIONS & WORKING RELATIONSHIPS:

• The Warehouse Leader is accountable for managing inbound and outbound logistics across the entire plant, including warehousing, material handling, and packaging operations, ensuring efficient material flow, inventory accuracy, and timely deliveries.
• Works in close coordination with cross-functional departments such as Production, Planning, Quality, Maintenance, Environmental Services, Finance, and Packaging to align logistics operations with plant-wide goals and compliance standards.
• Leads daily coordination and performance meetings with stakeholders including Materials Planning, Packaging, Logistics, Safety, Warehouse Supervisors, and third-party service providers to ensure smooth execution of day-to-day operations and to identify opportunities for continuous improvement.
• Engages in regular briefings with logistics and manpower service providers to manage resource allocation, maintain adherence to schedules, and proactively address operational challenges.
• Partners with the Finance and Quality teams to ensure cost-effective operations, compliance with internal controls, and adherence to quality standards in logistics and packaging processes.

Performance INDICATORS (INDICATIVE):

The Warehouse Leader is responsible for achieving key performance goals in their areas of accountability, driving operational excellence and continuous improvement:

Continuous Improvement

• Champions a Kaizen culture within the team, encouraging all direct and functional reports to participate in continuous improvement activities.
• Maintains a comprehensive log of Kaizen initiatives and tracks the progress and implementation of improvement actions.

Safety, Health & Environment (SHE)

• Ensures zero lost-time incidents by strictly enforcing safety protocols and fostering a safe working environment.
• Promotes the health and well-being of all personnel within the warehouse and logistics perimeter by executing all company-mandated safety and wellness measures.
• Guarantees full compliance with environmental KPIs, ensuring no gaps in environmental performance within the warehouse operations.

Delivery & Operational Efficiency

• Ensures timely adherence to schedules for inbound and outbound shipments, maintaining smooth flow of materials.
• Maintains accurate location control of all parts and inventory within the warehouse.
• Guarantees that parts are delivered in the correct quantities and on time to all feeder and assembly areas.
• Oversees preventive maintenance of all warehouse equipment, ensuring 100% availability as per schedule.
• Enforces FIFO (First-In-First-Out) standards to optimize inventory turnover.

Cost Management

• Meets labour efficiency targets in line with plant standards.
• Ensures stock accuracy and integrity of parts inventory.
• Controls consumable costs, maintaining expenditures within the approved budget.

QUALIFICATIONS, eXPERIENCE & SKILLS:

-Qualification:

Diploma/Bachelor of Engineering (Mechanical, Electrical, Automobile, Mechatronics )

Experience:

• 15 to 18 years of extensive experience in the supply chain domain, with a strong focus on warehouse management, cycle counting, line feeding, and overall logistics operations within an automobile OEM or Tier-1 supplier.
• Demonstrated capability to independently manage warehouse , Cycle count Operation New Project Management at the plant level, overseeing a team of 100 personnel and handling inventory valued at 20M€
• Experience working effectively in a diverse and multicultural plant environment.