Associate Manager - IE

Yokohama-ATG; Dahej; On-site; INR 600,000 - 1,200,000; Full time

Job summary

Yokohama-ATG in Dahej, Gujarat, seeks a Lean Manufacturing Specialist to drive plant optimization. The role focuses on identifying improvement projects via VSM, JIT, KANBAN, and 5S to reduce lead times and costs while coordinating manpower planning with senior management.

You will map processes, perform gap analyses with IE tools, and implement ergonomic layouts and MHE selections to boost productivity and ensure on-time delivery.

Qualifications

• Experience applying lean manufacturing principles to shop floor processes.
• Map and analyze processes to identify gaps using lean tools and motion economy basics.
• Plan manpower deployment to meet production demands with cost optimization.

Responsibilities

• Drive lean initiatives using VSM and JIT/KANBAN to reduce lead time.
• Advise management on manpower budgeting and hiring.
• Map processes and perform gap analysis with IE tools.
• Plan manpower deployment to meet production demand with optimized costs.
• Reduce TAT for inventory management.
• Improve productivity via cycle-time reduction and motion studies.
• Suggest ergonomic layouts and MHE selection.
• Analyze performance indicators and present to top management.
• Prepare plan vs actual reports for manufacturing KPIs.

Skills

Lean manufacturing

Value Stream Mapping (VSM)

JIT

KANBAN

Lead time reduction

5s

IE tools

Video analysis

ECRS techniques

MOST® / Mini MOST®

Job description

Key Activities & Responsibilities

• Driving lean manufacturing initiative for plant by identifying projects through VSM (Value Stream Mapping) & other tools like JIT, KANBAN, Lead time reduction, 5s etc.
• Advise the senior management on budget preparation of manpower and hiring.
• Conduct mapping and recording of processes/ activities, estimating gap analysis using lean tools & basic principles of motion economy.
• Plan and deploy manpower in respective direct & indirect areas based on work content estimation through the implementation of IE tools to meet production demands at optimized costs.
• Plan and finding solution for TAT reduction for inventory management.

Strategic

• Driving lean manufacturing initiative for plant by identifying projects through VSM (Value Stream Mapping) & other tools like JIT, KANBAN, Lead time reduction, 5s etc.
• Advise the senior management on budget preparation of manpower and hiring.
• Conduct mapping and recording of processes/ activities, estimating gap analysis using lean tools & basic principles of motion economy.
• Plan and deploy manpower in respective direct & indirect areas based on work content estimation through the implementation of IE tools to meet production demands at optimized costs.
• Plan and finding solution for TAT reduction for inventory management.

Productivity Improvement

• Work content calculation and suggestion for contract renewal.
• Video analysis for new & existing SKUs in back shifts.
• Drive set up change reduction projects with Video Analysis, ECRS etc. techniques.
• Drive automation projects to reduce man interference.
• Work on cycle time reduction on bottleneck machines by taking up man machine motion study.
• Use of Time & Motion Study, Basic MOST® and Mini MOST® for associate output improvement.

Ergonomics

• Rearrange layout for Muri free working.
• Independently work on improvement of layout of plants and offices.
• Suggest team for selection of MHEs as a part of ergonomic issue.

Documentation & Analysis

• Analyze performance indicators, trends and information from the daily processes and take necessary actions where appropriate.
• Conduct various analysis to ensure NVAs are reduced.
• Conduct the non-achieving parameter analysis and collectively action through DWM process.
• Perform detailed analysis on the reports generated and make recommendations and present it to the top management.
• Prepare plan v/s actual reports for targets achieved for manufacturing KPIs.
• Review and update Visual standards for improvement in work culture.

Team & Relationship Management

• Organize and develop an environment for shop floor associates to work according to optimum cycle time for highest output.
• Ensure inter plant communication for implementation of best practices in the plant.
• Represent plant team for machine selection and suggestion for layout management.
• Timely update to head for MIS & dashboard reviews.