Senior Manager - Operational Excellence

Location: Rudrapur

Work mode - 6 days

Role Purpose

The Senior Manager Operational Excellence will lead strategic and continuous improvement initiatives across manufacturing, supply chain, and operations, with a strong focus on productivity, quality, cost optimization, capacity utilization, and operational excellence.

The role will be responsible for:

- Driving Lean, Six Sigma and TPM initiatives to improve OEE and reduce operational losses.

- Leading cross-functional improvement projects aligned with business OGSM (Objectives, Goals, Strategies and Measures).

- Developing and implementing the Continuous Improvement strategy, governance, and operating rhythm.

- Building problem-solving capabilities across teams and coaching operational leaders.

- Monitoring key operational KPIs and providing actionable insights to senior leadership.

- Leading Value Engineering, Capacity Optimization, Line Balancing, and Digital Transformation initiatives.

- Strengthening the overall culture of continuous improvement and data-driven decision-making across the plant.

Key Responsibilities

1. Daily Management System

- Lead and strengthen the Daily Management System - POS across the plant.

- Drive adherence to POS standards and routines across functions.

- Identify and close gaps emerging from POS audits, ensuring achievement of target scores.

- Support plant leadership in establishing a strong performance management and review cadence.

- Use daily management data to identify performance gaps and prioritize improvement opportunities.

2. Problem Solving and Continuous Improvement

- Lead Root Cause Analysis (RCA) initiatives and support production teams in improving OEE and eliminating chronic losses.

- Drive structured problem-solving using Lean Six Sigma, statistical tools, and data-driven methodologies.

- Train and coach operators and teams.

- Develop an appreciation of the S&OP process and its linkage with operating hours, capacity utilization, and production planning.

- Lead and deliver cross-functional statistical improvement projects.

- Coach project managers and operational teams in structured problem-solving and project execution.

- Lead programs and manage portfolios of improvement initiatives across functions.

- Conduct Value Stream Mapping (VSM) and Line Balancing to identify and address chronic operational issues.

- Identify opportunities to improve productivity, reduce waste, optimize costs, and enhance quality.

3. Capability Development

- Mentor teams and build organizational capability in Continuous Improvement, Lean Six Sigma, and structured problem-solving.

- Develop and execute capability-building programs through the LSS Calendar cycle.

- Conduct skill assessments of operators and identify capability gaps.

- Lead targeted improvement and training programs to close identified capability gaps.

- Build a strong pipeline of internal CI champions and problem-solving practitioners.

4. Capacity Planning and Budgeting

- Develop a strong understanding of Capacity Planning and OEE Loss Trees and their linkage to short-term and long-term factory budgeting.

- Support capacity optimization initiatives based on demand, operating hours, OEE, and available resources.

- Develop an understanding of and contribute to budgeting processes related to: Energy, Labour, Maintenance, Repairs, and Operational efficiency.

- Identify opportunities to improve cost efficiency through productivity and operational improvement initiatives.

- Work collaboratively with multiple departments and functions to align operational improvement priorities with business requirements.

5. Digitization and Industry 4.0

- Lead Industry 4.0 and manufacturing digitization initiatives across the plant.

- Develop a strong understanding of the automation pyramid and its application within manufacturing environments.

- Identify opportunities to digitize manual processes, reports, and performance-monitoring systems.

- Lead small- to medium-scale digitization projects related to manufacturing reporting and operational performance.

- Leverage data and digital tools to improve visibility, decision-making, and operational efficiency.

Qualifications and Certifications

Educational Qualifications

- Bachelor's degree in Engineering or a related technical discipline.

- Master's degree preferred.

Certifications

- TPM Expert / Black Belt Certification from a recognized institution/body such as ASQ, JIPM, or equivalent.

- Lean Six Sigma certification preferred.

Experience

- 8 - 12 years of overall professional experience.

- Minimum 4 - 5 years of experience in FMCG / manufacturing environments, preferably in an Operational Excellence / Continuous Improvement role.

- Proven experience in leading Continuous Improvement programs and cross-functional teams.

- Demonstrated experience in driving measurable improvements in OEE, productivity, cost, quality, capacity utilization, and operational performance.

- Experience in leading multiple improvement projects/programs simultaneously.