Deputy Manager - Operational Excellence and Lean Manufacturing

Borgwarner Emission System; Chennai; On-site; INR 3,500,000 - 5,500,000; Full time

Job summary

Borgwarner Emission System in Chennai is seeking a Deputy Manager to lead Operational Excellence and Lean initiatives, driving productivity, quality, cost, delivery and safety across the plant. You will mentor cross‑functional teams, deploy Lean tools (Kaizen, VSM, 5S, SMED, Poka‑Yoke) and promote a continuous improvement mindset using DMAIC, A3 and PDCA.

The role requires engineering background and 10–15 years in industrial processes, with strong hands‑on experience in machining and assembly.

Qualifications

• Engineering degree required.
• Experience in industrial processes (machining and assembly).
• Mandatory: 5S / A3 / PDCA / 4 Steps.
• Mandatory: Lean Manufacturing.
• Mandatory: Kaizen.
• Preferred: DMAIC; Six Sigma; Kanban.
• Mandatory: Advanced MS Office.
• Preferred: SMED; 5 Whys.
• Language: Fluent English.
• Specialization: Industrial Engg/Mechanical.

Responsibilities

• Lead deployment of Lean tools to identify waste and drive productivity and cost savings.
• Implement Operational Excellence roadmap aligned to business goals and participate in leadership meetings.
• Lead structured problem solving (8D, RCA, A3, Six Sigma) and ensure issue closure.
• Drive TPM pillars and improve equipment uptime and OEE.
• Promote digital tools (MES, SCADA, Power BI) and standardize SOPs and best practices.
• Collaborate cross-functionally with Production, Quality, Maintenance, and Supply Chain on CI projects.

Skills

Lean Manufacturing

Kaizen

A3

PDCA

DMAIC

5S

VSM

SMED

Poka-Yoke

8D

7QC tools

RCA

5 Whys

Kanban

Total Productive Maintenance

Education

Engineering

Tools

Advanced MS Office

Job description

Deputy Manager – Operational Excellence & Lean Drive

Operational Excellence initiatives by implementing Lean Manufacturing, TPM, and Continuous Improvement methodologies to enhance productivity, quality, cost, delivery, and safety performance. Lead cross-functional teams to build a culture of continuous improvement and sustainable operational performance. Provide know-how and training to teams, support leadership and executive teams in developing OpEx strategies and promote a continuous improvement mindset along with waste elimination. Utilize tools such as DMAIC, PDCA, process mapping, Lean, Quick Setup (SMED), Ishikawa, 5 Whys, brainstorming, and A3. Promote a mindset of accountability, innovation, and continuous improvement to build a high-performing and resilient manufacturing organization.

1. Lean & Continuous Improvement: Lead deployment of Lean tools (Kaizen, VSM, 5S, SMED, Poka-Yoke), Identify and eliminate waste across processes, Drive productivity improvements and cost-saving initiatives in plant, Facilitate Kaizen events and CI workshops.
2. Operational Excellence Deployment: Implement Operational Excellence roadmap aligned to business goals, Representing the plant in Global Operational Excellence leadership monthly meetings & Forums, Support plant in achieving world-class manufacturing standards.
3. Problem Solving & Root Cause Analysis: Lead structured problem-solving (8D, RCA, A3, Six Sigma), Ensure closure of chronic issues through systemic improvements.
4. TPM Improvements: Drive Total Productive Maintenance (TPM) pillars, Support to Improve equipment uptime (OEE improvement).
5. Digitalization & Process Standardization: Promote use of digital and AI tools (MES, SCADA, Power BI dashboards), Standardize SOPs, processes, and best practices.
6. Cross-functional Collaboration: Work with Production, Quality, Maintenance, Supply Chain and Human Resource teams, Lead cross-functional improvement projects.

What we are looking for

• Education: Engineering
• Language: Fluent English
• Specialization: Industrial Engg/Mechanical
• Minimum Experience: 10-15 Years
• Experience in industrial processes (machining and assembly)
• Mandatory: 5S / A3 / PDCA / 4 Steps
• Mandatory: Advanced MS Office
• Preferred: SMED / 5 Whys
• Mandatory: Lean Manufacturing
• Preferred: Value Stream Mapping (VSM)
• Preferred: Black Belt / Green Belt / DMAIC Certification
• Preferred: Kanban
• Mandatory: Kaizen
• Mandatory: Total Productive Maintenance
• Mandatory: Problem solving tools & Techniques – 8D, 7QC tools

Experience Level: Senior Level