Operational Excellence Lead

ACG; Satara; On-site; INR 1,200,000 - 1,600,000; Full time

Job summary

ACG in Satara seeks a Continuous Improvement professional to drive manufacturing excellence. You will support CI strategy, plan and lead DMAIC projects, and collaborate with cross-functional teams to implement Kaizen initiatives across the plant.

The role emphasizes training and mentoring in Six Sigma, TPM, and problem-solving tools, with regular project reviews and stakeholder engagement to ensure measurable gains.

Qualifications

• BE/B-Tech degree required.
• MBA/M Tech (Operations/IE) preferred.
• 4–5 years of experience in CI/manufacturing.
• Black Belt Certification mandatory.

Responsibilities

• Support CI strategy and identify yearly improvement areas.
• Develop detailed project plans with project leaders for CI projects.
• Create assessment structures to measure CI outcomes against targets.
• Facilitate DMAIC activity plans and tracking for each project.
• Conduct Value Stream Mapping, bottleneck and cycle time studies.
• Lead Kaizen events and Small Group Activities to drive improvements.

Skills

Problem Solving Knowledge

Cross Functional Team Work

Six Sigma BB Certification

Microsoft Office

Knowledge of Minitab

Innovation

Quality and Service Orientation

Drive for Consistent Results

Corporate Etiquette

Communication

TPM & pillar handling capabilities

Education

BE/B-Tech

MBA/M Tech (Operations/IE)

Tools

Minitab

Microsoft Office

Job description

A. Job Objective

• Identify and Drive Continuous Improvement projects through structured analysis to improve plant performance metrics
• Develop, engage and enable people for analytical thinking, improve individual skillsets across functions, build the capability to improve the application of problem solving tools in order to be able to adopt the benchmarked manufacturing excellence practices

B. Primary responsibilities

Strategic and planning

• Support the CI manager in execution of CI strategy
• Identify yearly Improvement areas and accordingly plan projects for the plant
• Create an assessment structure to measure the effectiveness of CI initiatives vis-a-vis the envisaged project outcome

Functional

Core

• Facilitate and develop detailed project plans along with project leaders for all identified CI projects in the plant including DMAIC activity plan for each project
• Analyse project data and conduct observation studies in every project
• Coordinate action plans for project delivery (for every CI project at the plant)
• Monitor and communicate project status periodically to all stakeholders
• Support in execution of 6 sigma (Black Belt/Green Belt/Yellow Belt) Training Calendar.
• Facilitate implementation of Kaizen Mechanisms to drive small improvements across the plant
• Facilitate Small Group Activity teams / Quality Circle Teams for Problem Solving.
• Conduct Value Stream Mapping/ Bottleneck and Cycle Time studies for Process Improvements
• Monitor daily project wise actionable/observation studies/trials and the project participation of the stakeholders through various systemic methods
• Support Manufacturing/Production Project Leaders to conduct trials as per protocols
• Creation of training module for various CI skill sets (TPM, Six Sigma, etc.)

Internal process

• Facilitate weekly Project Reviews with Plant Project team, Plant Head and Functional CIC Head
• Facilitate monthly Plant Steering committee reviews
• Escalate delays and non-compliances to CI Manager and plant head.
• Creation of Projects Dashboard for Plant Heads Review
• Conduct GEMBA walks with Mfg. Head to regularly identify potential areas of improvements and track the implementation of the same.
• Conduct Kaizen Idea Workshops across the plant

People development

• Train the identified people by respective process owners for Kaizen. Identify & develop project teams for analytics and sustenance of improvements
• Support in design and execution of Quarterly Kaizen Events, yearly Six Sigma Project competitions for employees.

C. Key Result Areas

• No of processes standardized through various CI projects
• No. of Kaizen Projects Completed vs planned
• No. of People Trained & Certified in Six Sigma Methodology against planned
• Compliance to Kaizen Idea Workshops & Events as per Plan
• GEMBA Walks Improvements Planned vs Actuals

D. Key Interfaces

Internal Interfaces

External Interfaces

• Production
• Quality
• Maintenance
• Post Manufacturing
• HR
• Central CIC

• Project Steering Committee Stake Holders
• External Consultants
• External Vendors

E. Competency

Technical Competency T Compass

Leadership Competency L Compass

Competency

Level

Competency

Level

Problem Solving Knowledge

Cross Functional Team Work

Six Sigma BB Certification

Problem Solving

Microsoft Office

Advanced

Communication

Knowledge of Minitab & Tools

Innovation

TPM & pillar handling capabilities

Corporate Etiquette

Quality and Service Orientation

Drive for Consistent Results

F. Educational and Experience Requirements

Minimum Requirement

Desired

Level of Education

• BE/B-Tech

• MBA/M Tech (Operations/IE)

Experience

• 4 to 5 Years

• 4-5 years

Must Be

• Black Belt Certified

• Certified PMP, Data Analytics, Lean