DGM - APS & Lean Management

Agratas – A Tata Enterprise; Ahmedabad District; On-site; INR 350,000 - 520,000; Full time

Job summary

Agratas – A Tata Enterprise is seeking a Senior Production System Leader to design, deploy and sustain the Agratas Production System across a cell plant. You will drive lean cultural change, embed standardised work, and lead cross-functional teams from Electrode to End-of-Line.

You will champion VSM, 5S, line balancing, and Kanban while coaching leaders in continuous improvement and ensuring measurable savings across PPSQDCME metrics.

Qualifications

• Engineering degree in Mechanical/Industrial/Manufacturing
• Lean Six Sigma Green Belt (minimum); Black Belt preferred
• Formal Lean / Production System training from automotive OEM, Tier-1 or recognised lean institute
• Experience in high-volume manufacturing environments

Responsibilities

• Design, develop, and implement APS framework aligned with Lean principles
• Lead end-to-end lean transformation across shop floors
• Conduct current-state and future-state VSMs to identify waste and improvement opportunities
• Establish SOPs, standardised work and operator work instructions
• Plan and drive Kaizen events and CI projects with measurable savings
• Design and sustain 5S, visual management, and production control boards
• Lead line balancing and flow optimization to reduce WIP and improve throughput
• Develop lean training programmes and coach internal lean champions
• Collaborate with Manufacturing Engineering, Quality, Maintenance, Launch, Supply Chain and HR

Skills

Lean Manufacturing

Six Sigma Green Belt

OEE improvement

Kanban / Pull system

Data analysis (Minitab)

Advanced Excel

Project Management

Stakeholder coaching

Education

Engineering degree in Mechanical/Industrial/Manufacturing

Lean Six Sigma Green Belt (minimum)

Tools

MS Excel (advanced)

PowerPoint

Minitab

Job description

Purpose of the Role
Managing and leading a cross-functional team of engineers and production specialists to design, deploy, and sustain a world-class Production System (PS) grounded in Lean Manufacturing principles. The role is pivotal in driving cultural and operational transformation across the cell manufacturing plant by embedding lean tools, methodologies, and a continuous improvement mindset at every level of the organisation. The DGM will be responsible for developing and implementing the Agratas Production System (APS) framework, standardising work processes, eliminating waste, and enabling measurable improvements in people, safety, quality, delivery, cost, maintenance, energy and environment (PPSQDCMEE). The role requires close collaboration with production, maintenance, quality, supply chain, and HR functions, as well as engagement with external partners and benchmarking organisations.

Key Responsibility Areas

Technical / Functional

• Agratas Production System (APS) Development & Deployment: Design, develop, and implement a comprehensive Production System framework aligned with Lean principles (LEAN MANUFACTURING -PS-derived), covering all manufacturing areas of the cell plant.
• Lean Transformation Leadership: Lead end-to-end lean transformation initiatives across all shop floors, including Electrode, Assembly, Formation, and End-of-Line, ensuring sustained change management and cultural adoption.
• Value Stream Mapping (VSM): Conduct detailed current-state and future-state VSM exercises to identify waste, inefficiencies, and improvement opportunities across the manufacturing value chain.
• Standardised Work & Work Instruction Management: Establish, maintain, and continuously improve Standard Operating Procedures (SOPs), standardised work documents, and operator work instructions.
• Kaizen & Continuous Improvement Programme: Plan, facilitate, and drive structured Kaizen events, improvement workshops, and CI projects targeting PSQDCME metrics. Track and report savings and impact.
• 5S & Visual Management: Design and sustain 5S systems, visual factory standards, shadow boards, andon systems, and production control boards across all production areas.
• Line Balancing & Flow Optimisation: Lead cycle time studies, takt time analysis, line balancing exercises, and layout optimisation to enhance throughput and reduce WIP

Knowledge Generic

IT SkillsExperience with layout design, ergonomics, and material flow optimisation in greenfield or brownfield plants is desirable

• Proficiency in MS Excel (advanced), PowerPoint, and data analysis tools such as Minitab and project management.
• Familiarity with digital lean tools, plant simulation software, or Industry 4.0 platforms is an advantage.
• Good presentation and facilitation skills for senior stakeholder engagement and shop-floor coaching.
• Strong understanding of the Lean manufacturing - Production System philosophy and its application in high-volume high-speed discrete or process manufacturing.
• Proven experience in leading large-scale lean transformations with measurable business impact.
• Knowledge of statistical process control (SPC), Six Sigma methodologies (Black Belt preferred), and problem-solving tools (A3, 8D, PDCA).
• Understanding of battery cell manufacturing processes (Mixing, Coating, Calendaring, Slitting, Assembly, Formation) is desirable.
• OEE Improvement: Drive Overall Equipment Effectiveness (OEE) improvement programmes in collaboration with maintenance and production teams; identify and eliminate losses across availability, performance, and quality.
• Pull System & Kanban Implementation: Design and implement pull-based material flow systems, supermarkets, and Kanban replenishment loops across internal logistics and production areas.
• People Development & Lean Capability Building: Develop and deliver lean training programmes for all levels of the organisation, from operator to senior management. Coach and mentor internal lean champions.
• Production System Governance & Lean Maturity Model Adherence: Establish LMM frameworks to assess PS maturity, compliance, and sustainability. Drive corrective action plans based on findings.
• Cross-functional Collaboration: Work closely with Manufacturing Engineering, Quality, Maintenance, Launch Integration, Supply Chain, and HR to align lean initiatives with overall plant and business objectives.
• Benchmarking & Best Practice: Lead external benchmarking activities across automotive and adjacent industries. Adapt and integrate best practices into the Agratas Production System.
• Project Management: Manage multiple lean and PS projects simultaneously, ensuring on-time delivery, resource allocation, budget adherence, and stakeholder communication.
• KPI Monitoring & Reporting: Define, track, and report on lean KPIs including lead time, cycle time, defect rates, first-pass yield, scrap, OEE, and cost savings to senior leadership.
• Establish metrics: Ability to identify and drive the drill down of organisational metrics to the front-line leadership level
• Ability to integrate concepts such as TPM with the broader Production System and lean transformation

Job Context Specific

Mandatory / Desired

• Engineering degree in Mechanical / Industrial Engineering / Manufacturing Engineering or equivalent.
• Lean Six Sigma Green Belt (minimum); Black Belt preferred.
• Formal Lean / Production System training from an automotive OEM, Tier-1 supplier, or recognised lean institute.

Mandatory Desired

• 15 to 20 years of experience in manufacturing operations with at least 8 to 10 years in a dedicated Lean / Production System role.
• Demonstrated track record of implementing Production Systems in high-volume manufacturing industries such as Automotive, Battery / EV, Pharma, Electronics, FMCG, Tyre, or Aerospace.
• Proven experience in building and leading lean teams, coaching frontline supervisors and managers, and driving cultural change.
• Experience working in greenfield manufacturing set-ups or transformative lean journeys from inception is strongly preferred.

Knowledge Specific