Manufacturing and Services Consultant

1. JOB OBJECTIVE

Lead and deliver transformative consulting engagements focused on Organizational Excellence (OE) and Operational Excellence (OpEx) for manufacturing and service sector clients. Drive sustainable performance improvements through the implementation of structured problem-solving methodologies, lean principles, and continuous improvement frameworks to optimize productivity, quality, cost, delivery, and organizational culture.

2. KEY RESPONSIBILITY AREASA. Strategic Consulting & Assessment

·  Conduct comprehensive organizational and operational assessments to identify improvement opportunities across manufacturing and service operations

·  Analyze business performance, research industry trends, and benchmark against best-in-class practices

·  Develop customized Operational Excellence strategies aligned with the client's business objectives and growth plans

·  Facilitate goal deployment through cascading business goals to functional and individual performance targets

·  Design and implement change management initiatives to drive organizational transformation

·  Prepare annual OE/OpEx roadmaps and monitor progress against defined milestones

B. Process Optimization & Improvement

·  Conduct maturity assessments using frameworks such as Lean, Six Sigma, TPM, WCM, and TQM

·  Lead process mapping, value stream analysis, and identification of waste (Muda, Mura, Muri) across operations

·  Facilitate identification and selection of Focused Improvement Projects (FIPs) with quantifiable business impact

·  Implement lean manufacturing principles including 5S, Kaizen, Kanban, Just-In-Time, SMED, Poka-Yoke, and VSM

·  Conduct root cause analysis (RCA) sessions using structured problem-solving tools (5 Whys, Fishbone, 8D, A3)

·  Reengineer business processes to improve efficiency, effectiveness, and customer value delivery

·  Design and deploy Total Productive Maintenance (TPM) programs to maximize asset reliability and OEE

C. Project Management & Execution

·  Track accrued and annualized savings from improvement projects and validate them through financial reconciliation

·  Prepare and present progress reports, insights, and recommendations to C-level executives and senior management

·  Facilitate Daily Management Team (DMT) meetings, ensuring structured problem-solving and data-driven decision-making

·  Monitor Key Process Output Variables (KPOVs) and Key Performance Indicators (KPIs) achievement

D. Quality Management & Compliance

·  Develop and implement Quality Management Systems to reduce defects, rework, and customer complaints

·  Establish robust quality control procedures, testing protocols, and inspection standards

·  Drive initiatives to improve First Pass Yield (FPY), reduce Cost of Poor Quality (COPQ)

·  Ensure compliance with industry standards, regulatory requirements, and SOPs

·  Implement statistical process control (SPC) and Six Sigma DMAIC methodologies for quality improvement

E. Technology Integration & Digital Transformation

·  Advise clients on the adoption of Industry 4.0 technologies, automation, IoT, and digital manufacturing solutions

·  Implement Operational Technology (OT) solutions, including MES, SCADA, and real-time performance monitoring systems

·  Leverage data analytics, business intelligence, and advanced analytics to drive performance insights

·  Explore opportunities for workflow automation and Robotic Process Automation (RPA)

F. Capability Building & Change Management

·  Design and deliver training programs to build internal capabilities in OpEx methodologies and tools

·  Coach and mentor client leadership teams, functional heads, and frontline teams on a continuous improvement culture

·  Facilitate idea harvesting, Kaizen events, and employee engagement initiatives

·  Develop reward and recognition programs to sustain an improvement culture

·   Conduct knowledge management activities, including documentation, SOP creation, and best practice sharing

3. QUALIFICATIONS & EDUCATIONAL REQUIREMENTS
Minimum Qualifications

·       
Bachelor's Degree
: B.E./B.Tech in Mechanical, Industrial, Manufacturing, or Electrical Engineering; OR Bachelor's in Operations Management.

·       
Advanced Degree (Preferred)
: MBA in Operations Management, Master's in Industrial Engineering, or Master's in Manufacturing Engineering

Certifications (Preferred)

o Lean Six Sigma Green Belt or Black Belt certification

o Certified Manager of Quality/Organizational Excellence (CMQ/OE - ASQ)

o Lean Manufacturing Certification

o TPM Facilitator/Practitioner Certification

o EFQM Excellence Practitioner

o Organization Development Certified Consultant (ODCC)

o ISO 9001 Lead Auditor Certification

4. EXPERIENCE REQUIREMENTS
Minimum Experience

Relevant experience in manufacturing operations, process improvement, or management consulting

Hands-on experience in implementing Lean, Six Sigma, TPM, or WCM programs

A consulting role or leading cross-functional improvement projects

Industry Experience (Preferred)

Automotive, Aerospace, Consumer Goods, Electronics, Pharmaceuticals, Food & Beverage, Process Industries

Functional Expertise

·    Deep knowledge of manufacturing processes: Planning, Production, Maintenance, Quality, Supply Chain, Logistics

·    Proven track record of delivering measurable business impact through OpEx programs

·    Experience managing large-scale transformation projects across multiple sites/geographies

·    Exposure to digital manufacturing, Industry 4.0, MES, ERP systems manufacturing environment.