Deputy Manager - Operational Excellence & Lean

BorgWarner; Chennai District; On-site; INR 1,400,000 - 3,200,000; Full time

Job summary

BorgWarner seeks an experienced Operational Excellence Lead to drive Lean and Continuous Improvement across manufacturing processes in Chennai. You will lead cross-functional teams, deploy Kaizen, VSM, 5S, SMED, and PDCA, and mentor teams in advanced problem solving using 8D, RCA, and A3 methodologies.

The role emphasizes waste elimination, OEE improvements, and digitalization with MES/SCADA and Power BI dashboards, while collaborating with Production, Quality, Maintenance, and Supply Chain to

Qualifications

• Engineering degree or equivalent.
• Fluent English communication.
• Industrial engineering specialization preferred.
• 10–15 years of experience in manufacturing/ops excellence.

Responsibilities

• Lead deployment of Lean tools (Kaizen, VSM, 5S, SMED, Poka-Yoke).
• Identify and eliminate waste; drive productivity and cost-saving initiatives.
• Represent and align OE roadmap with business goals; participate in global leadership meetings.
• Lead structured problem solving (8D, RCA, A3, Six Sigma).
• Drive TPM improvements and OEE enhancement.
• Promote digital tools (MES, SCADA, Power BI) and standardized processes.
• Collaborate cross-functionally with Production, Quality, Maintenance, Supply Chain and HR.

Skills

Lean Manufacturing

Continuous Improvement

Kaizen

VSM

5S

SMED

A3

DMAIC

PDCA

8D

Education

Engineering

Tools

MES

SCADA

Power BI

MS Office

Job description

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.

Job Responsibilities

• 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
• 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
• Problem Solving & Root Cause Analysis Lead structured problem-solving (8D, RCA, A3, Six Sigma) Ensure closure of chronic issues through systemic improvements
• TPM Improvements Drive Total Productive Maintenance (TPM) pillars Support to Improve equipment uptime (OEE improvement)
• Digitalization & Process Standardization Promote use of digital and AI tools (MES, SCADA, Power BI dashboards) Standardize SOPs, processes, and best practices
• 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

Technical Competencies

• Technical Competencies Competency Requirement Level 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 Mandatory

BorgWarner is a global product leader in delivering innovative and sustainable mobility solutions. We are a company of innovators and independent thinkers that brings together talented employees, meaningful work and amazing technology in a unique environment. At BorgWarner we constantly work towards our vision of a clean and energy-efficient world.

Our Culture BorgWarner promotes and nurtures a diverse and inclusive environment, honors integrity, strives for excellence, commits to responsibility for our communities and the environment, and builds on the power of collaboration. We believe the health and safety of our employees are a top priority.

Career Opportunities We manage talent as seriously as we manage our businesses and encourage you to learn about our proud history, strong culture, technologies, and vision for the future. We offer positions locally and globally with over 90 locations in 19 countries.