Lead - Operational Excellence, Shirwal, ACG Capsules

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

Job summary

ACG Capsules in Shirwal seeks a Lead - Operational Excellence to drive continuous improvement across the plant. You will lead CI projects, build Lean Six Sigma capability, and implement Lean Daily Management with cross-functional teams to deliver measurable gains.

You will coordinate data collection, trials and action planning, develop dashboards in Excel/Power BI, and support digital tools like Power Apps.

Qualifications

• 3+ years in Operational Excellence / Continuous Improvement
• Overall, 5 years in manufacturing / Continuous Improvement experience
• Experience leading cross-functional teams and CI projects
• Knowledge of DMAIC, RCA, and standard Lean tools

Responsibilities

• Execute Lean Six Sigma, Kaizen and structured problem‑solving projects
• Develop data collection plans and conduct GEMBA/observation studies
• Apply CI tools (RCA, Pareto, 5-Why, Fishbone, Cp/Cpk, MSA, VSM, SMED, DILO) for improvements
• Coordinate with Manufacturing, Quality, Engineering and Maintenance teams
• Drive Lean Daily Management System (LDMS) and KPI reviews
• Facilitate Kaizen, Poka-Yoke, Visual Management and Standard Work
• Develop CI dashboards using Excel and Power BI
• Support digitalization of shop-floor data collection and CI processes

Skills

Lean Six Sigma

Kaizen

Data analysis

Project leadership

LDMS

Tools

Power BI

Excel

Power Apps

Job description

Lead - Operational Excellence, Shirwal, ACG Capsules

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

Grade: M09/M08

Reports to: Operational Excellence Lead

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 elevate 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.
• 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
• People trained as per the CI / Technical Training Calendar
• LDMS / KPI review adherence and closure of improvement actions

Key Interfaces

• Internal 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

Educational and Experience Requirements

• 3+ years in Operational Excellence / Continuous Improvement
• Overall, 5 years in manufacturing / Continuous Improvement experience