Industrial Engineering Manager

Bull Machines; Coimbatore District; On-site; INR 900,000 - 1,500,000; Full time

Job summary

Bull Machines is seeking an experienced Process Engineer to optimize operations in the Coimbatore region. The role focuses on Lean manufacturing, Six Sigma projects, and end-to-end process improvements across assembly and fabrication.

You will lead time-and-motion studies, line balancing, and VSM to remove bottlenecks, develop SOPs, and drive Kaizen-based cost reductions on the shop floor.

Qualifications

• Assembly and heavy fabrication experience is required.

Responsibilities

• Analyze end-to-end production workflows using Lean and Six Sigma.

Skills

Lean Manufacturing

Six Sigma

Time-and-motion studies

Line balancing

Value Stream Mapping

SOPs

Standard work

OEE

Kaizen

Cross-functional collaboration

Tools

MOST

Yamazumi Chart

MTM

Standard Work Combination Sheet

Operator Balance Chart

VSM

Spaghetti Diagram

Flow Process Chart

Makigami Diagram

Heijunka Box

Andon Board

Kanban System

CAD software

Job description

Process Engineering & Operational Excellence:

Assembly & Heavy Fabrication experience is must. Analyze end-to-end operational workflows using Lean Manufacturing and Six Sigma methodologies.

Conduct time-and-motion studies- MOST time study, line balancing- Yamazumi chart, and Value Stream Mapping (VSM) to eliminate non-value-added steps and bottlenecks.Establish, standardize, and audit Standard Operating Procedures (SOPs) and standard work instructions across production operations.

Work Measurement and Line Balancing Tools

• MOST (Maynard Operation Sequence Technique)
• Yamazumi Chart
• MTM (Methods-Time Measurement)
• Standard Work Combination Sheet
• Operator Balance Chart (OBC)

Flow and Layout Mapping Tools:

• VSM
• Spaghetti and String Diagram
• Flow Process Chart
• Makigami Diagram

Visual Management and Scheduling Tools:

• Heijunka Box
• Andon Board
• Kanban System

Capacity, Layout & Resource Planning:

Perform capacity modeling, labor requirement analysis, and machine utilization tracking to optimize staffing and asset deployment.

Design and re-engineer plant layouts, material flow pathways, and workstation ergonomics using CAD software to minimize material handling costs.

Define and track key performance indicators (KPIs) such as Overall Equipment Effectiveness (OEE), takt time, cycle time, and labor productivity.

Cost Reduction & Continuous Improvement:

Identify and implement continuous improvement (Kaizen) projects to reduce operational expenditures, material scrap, and rework rates.

Conduct feasibility studies, payback analysis, and business cases for process improvement initiatives.

Drive waste reduction across all operational areas using the 8 Wastes framework (TIMWOODS).

Project Management & Automation:

Lead capital expenditure (CapEx) projects from concept design to machinery procurement, installation, line commissioning, and ramp-up.

Evaluate and integrate Industry 4.0 technologies, robotics, Automated Guided Vehicles (AGVs), and Manufacturing Execution Systems (MES).

Manage project budgets, schedules, vendor relationships, and equipment acceptance testing.

Leadership & Cross-Functional Collaboration:

Directly manage, mentor, and assign priorities to a team of industrial engineers, process engineers, and technical specialists.

Collaborate closely with Operations, Quality Assurance, Supply Chain, Maintenance, and EHS (Environmental Health and Safety) teams to resolve production issues.

Lead change management efforts to embed an operational excellence culture on the shop floor.