DGM - APS & Lean Management

Agratas – A Tata Enterprise; Ahmedabad District; On-site; INR 1,500,000 - 2,100,000; Full time

Job summary

Agratas – A Tata Enterprise is seeking a senior leader to develop and deploy the Agratas Production System (APS) grounded in Lean Manufacturing. You will lead a cross-functional team to embed lean culture, standardise work, and drive measurable improvements in safety, quality, delivery, and cost across the production cell.

The role requires strong experience in lean transformations, VSM, and TPM-like practices, with collaboration across Manufacturing Engineering, Quality, Maintenance, Supply

Qualifications

• In-depth knowledge of core Lean tools (VSM, 5S, SMED, Poka-Yoke, Kaizen, Kanban, Heijunka, Jidoka, Standardised Work).
• Strong understanding of Lean Production System philosophy and its application in high-volume manufacturing.
• Experience leading large-scale lean transformations with measurable business impact.

Responsibilities

• Design, develop, and implement APS framework aligned with Lean principles across all cell manufacturing areas.
• Lead end-to-end lean transformation initiatives across shop floors ensuring sustained change and cultural adoption.
• Conduct current/future-state VSM to identify waste and improvement opportunities.
• Establish and continuously improve SOPs, standardised work, and operator work instructions.
• Plan and drive Kaizen events and CI projects targeting PSQDCME metrics with tracked savings.

Skills

Lean Manufacturing

Value Stream Mapping

OEE Improvement

Project Management

Stakeholder Engagement

MS Excel

Tools

Minitab

Plant Simulation

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

• 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.
• 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.
• Knowledge Generic

Knowledge Generic

IT Skills

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.

PREREQUISITES TECHNICAL KNOWLEDGE

In-depth knowledge and hands-on experience of core Lean tools: VSM, 5S, SMED, Poka-Yoke, Kaizen, Kanban, Heijunka, Jidoka, and Standardised Work. 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).

Job Context Specific

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.