Lead - Operational Excellence, Shirwal, ACG Capsules

ACG World; Satara; On-site; INR 1,500,000 - 2,100,000; Full time

Job summary

ACG Capsules in Shirwal is seeking a Senior Engineer – Operational Excellence to lead CI projects and drive Lean initiatives on the plant floor. You will coordinate cross-functional teams, collect data, and apply Six Sigma methods to improve quality, productivity and safety.

The role requires hands-on GEMBA observations, strong data analytics in Excel/Power BI, and the ability to train teams in Lean tools. You will contribute to the OpEx roadmap, track KPIs and ensure timely delivery of

Qualifications

• BE/BTech in Mechanical Engineering required.
• Overall, 5 years in manufacturing / Continuous Improvement experience.
• Six Sigma Green Belt and Black Belt certifications.
• Experience with Lean tools and Kaizen.
• Ability to lead cross-functional teams.

Responsibilities

• Execute Lean Six Sigma, Kaizen, and structured problem-solving projects.
• Develop data collection plans and conduct GEMBA/observation studies, trials and process analysis.
• Apply RCA, Pareto, 5-Why, Fishbone, Cp/Cpk, MSA, VSM, SMED, DILO for process, quality, productivity and reliability improvement.
• Coordinate with Manufacturing, Quality, Engineering and Maintenance teams for corrective actions and engineering solutions.
• Drive Lean Daily Management System (LDMS), KPI reviews, action tracking and escalation routines.
• Facilitate Kaizen, Poka-Yoke, Visual Management, Standard Work and shop-floor improvement activities.
• Develop and maintain CI project dashboards and KPI reports using Excel and Power BI.
• Support digitalization of shop-floor data collection and CI processes using Power Apps and other approved digital solutions.
• Support Technical Training, Lean Six Sigma capability building, Small Group Activities / Quality Circles and CI events.
• Support 5S audits and track improvement actions with process owners.

Skills

Lean Six Sigma

Data analysis

Gemba walks

Cross-functional leadership

Power BI

Power Apps

Problem solving

Education

BE/BTech – Mech Engg

Tools

Minitab

Excel

Power Apps

Job description

Position Title: Engineer/Senior Engineer – Operational Excellence (Shirwal), ACG Capsules

Organization Context

Position Title

Senior Engineer – Operational Excellence, ACG Capsules

Grade

M09/M08

Department

Operational Excellence

Location

Shirwal

Reports To

Operational Excellence Lead

Reported By

ACG is the world’s only integrated pharma manufacturing solutions company. We are headquartered in Mumbai, India. ACG has a presence in over 100 countries with its products and services that strive to provide world‑class technology across multiple domains. We offer a complete range of solutions beginning with empty capsules; granulation and tablet coating; capsule filling; tabletting; packaging films; blister packing and carton packing to the end‑of‑line solutions and track and trace systems.

We have an opportunity in ACG Capsules / ACG Engineering / ACG Pharma Packaging / ACG Inspection.

• Job Objective

• Execute Continuous Improvement and Operational Excellence projects through structured data collection, analysis and implementation of sustainable actions.
• Lead cross-functional teams in data collection, observation studies, trials and action planning to ensure timely delivery of CI projects.
• Drive Lean Daily Management, Kaizen and change-management activities in line with the plant OpEx roadmap.
• Build plant capability in Lean Six Sigma, problem solving, data analysis and continuous improvement practices.
• Primary responsibilities

Strategic and planning

• Support execution of the Plant Operational Excellence strategy and identify improvement opportunities.
• Participate in improvement‑area identification and execute agreed CI projects with defined targets and timelines.

Functional – Core

• Execute Lean Six Sigma, Kaizen and structured problem‑solving projects and measure effectiveness against project outcomes.
• Develop data collection plans and conduct GEMBA/observation studies, trials and process analysis using appropriate CI and statistical tools.
• Apply RCA, Pareto, 5-Why, Fishbone, Cp/Cpk, MSA, VSM, SMED, DILO and Motion Study for process, quality, productivity and reliability improvement.
• Coordinate with Manufacturing, Quality, Engineering and Maintenance teams for corrective actions and engineering solutions.
• Drive Lean Daily Management System (LDMS), KPI reviews, action tracking and escalation routines.
• Facilitate Kaizen, Poka-Yoke, Visual Management, Standard Work and shop-floor improvement activities.
• Develop and maintain CI project dashboards and KPI reports using Excel and Power BI.
• Support digitalization of shop-floor data collection and CI processes using Power Apps and other approved digital solutions.
• Support Technical Training, Lean Six Sigma capability building, Small Group Activities / Quality Circles and CI events.
• Support 5S audits and track improvement actions with process owners.

Internal process

• Monitor project progress, actions and risks and escalate delays or non‑compliances to the Operational Excellence Manager and HODs.
• Prepare project status, implementation and benefit updates for Plant Operational Excellence reviews.
• Maintain CI project, Kaizen, LDMS and related documentation, trackers and closure records.

People development

• Train and coach associates and process owners in Lean Six Sigma, RCA, Kaizen, problem solving and Daily Management practices.
• Support execution of the Technical Training Calendar and development of CI capability across the plant.
• Support quarterly Kaizen events and Six Sigma project competitions for associates.
• Key Result Areas

• Continuous Improvement projects completed vs. planned and effectiveness against agreed targets
• Processes standardized through CI projects, Standard Work, Visual Management and Poka-Yoke
• Kaizen projects completed vs. planned
• People trained as per the CI / Technical Training Calendar
• LDMS / KPI review adherence and closure of improvement actions
• 5S / GEMBA improvement actions completed vs. planned
• Key Interfaces

Internal Interfaces

External Interfaces

Manufacturing

Quality

Engineering

Maintenance

Post Manufacturing

HR

Plant SCM

Plant Finance

Central Operational Excellence / CIC

Project Steering Committee Stakeholders

External Consultants

External Vendors

• ACG Persona

Technical Competency – T Compass

Leadership Competency – L Compass

Persona

Level

Competency

Level

Problem Solving Knowledge

4

Integrator

4

Six Sigma GB / Black Belt Certification

3

Partner

2

Microsoft Office / Data Analytics

4

Innovator

3

Minitab & Statistical / Lean Tools

2

Entrepreneur

2

TPM / Reliability & CI Pillar Handling

2

Builder

1

• Educational and Experience Requirements

Minimum Requirement

Desired

Level of Education

BE/B-Tech – Mech Engg

BE/B-Tech – Mech Engg

Experience

3+ years in Operational Excellence / Continuous Improvement

Overall, 5 years in manufacturing / Continuous Improvement experience

Must Be

Six Sigma Green Belt Certified

Six Sigma Black Belt Certified