Lead Operational Excellence Dahanu

A. Job ObjectiveDeliver Continuous Improvement projects through structured analysis and improve plant performance metricsProvide support to CI project leaders in creating project plans, analytics, conducting observation studies, develop control plans to ensure on time project delivery.Design and implement change management events in line with CI roadmapSupport in driving the technical and analytical capability building for the plant to achieve operational excellenceB. Primary responsibilitiesStrategic and planningSupport the Plant OPEX lead in execution of Plant OPEX strategyIdentify Improvement areas and plan improvement projects and CI initiatives for the plantCreate an assessment structure to measure the effectiveness of CI initiatives vis-a-vis the envisaged project outcomePlan & Align resources (reading modules) for technical trainings and provide support as neededFunctionalCoreFacilitate cross functional focussed Improvement projects using Lean and Six Sigma complex problem-solving methodology.Analyse Continuous Improvement project data using Six Sigma statistical tools and conduct Gemba observation studies for cause validation and improvement actions.Facilitate and develop detailed project plans along with project leaders for Lean and Six Sigma improvement projectsCoordinate and follow up for action plans and ensure on time delivery of CI projectsMonitor daily project wise actionable/observation studies/trials and the project participation of the stakeholders through various systemic methodsMonitor and communicate project status periodically to all stakeholdersFacilitate Small Group Activity (Quality Circle) teams for Problem Solving.Facilitate implementation of Kaizen to drive small improvements across the plantFacilitate implementation of Best Practice Replication across the plantsFacilitate implementation of Low-cost Engineering control solutions to sustenance of improvementsConduct Value Stream Mapping, Bottleneck Process studies for ImprovementsLead implementation of Lean Daily Management system and Tier Reviews to drive Autonomous Shopfloor performance improvements across the plantCreation of training modules for various CI skill sets (Lean,Six Sigma, Kaizen,TPM)Plan and Execute Six Sigma, Lean, Kaizen, TPM trainings.Execute and support in imparting Technical Trainings as per training CalendarInternal processFacilitate weekly Project Reviews with Plant Project team, Plant Mfg Head, Plant Head, Plant Opex Lead, OPEX Program Manager and Global OPEX HeadFacilitate monthly Plant Steering committee reviewsEscalate delays, challenges and non-compliances in implementing various CI initiatives to Plant Mfg Head, OPEX Program Manager and Plant Head.Create CI Projects Dashboard for Review by Plant Head and Top managementConduct GEMBA walks with HODs to regularly identify potential areas of improvements and track the implementation of the same.Conduct Gemba Kaizen Idea Workshops and Kaizen initiatives across the plantCollaborate with all relevant stakeholders in executing, monitoring and tracking of Technical TrainingPeople developmentTrain the people across all departments on Gemba Kaizens to develop CI culture.Support in design and execution of Quarterly Kaizen Events, yearly Six Sigma Project competitions for employees.Identify & develop project teams for analytics and sustenance of improvements.C. Key Result AreasNo. of high impact Continuous Improvement Projects completed vs planned (*provided this is reflected in the respective JD of Plant Head & Function Head)No. of Kaizen and Quality Circle Projects Completed vs plannedNo of processes standardized through various CI projectsNo. of People Trained in CI tools and technique, technical skill set against plannedCompliance to Kaizen Idea Workshops & Events as per PlanGEMBA Walks Improvements Planned vs ActualsOverall competency enhancement level of associates Planned vs Actual