Process Excellence Manager

Wakefit Innovations; Krishnagiri District; On-site; INR 900,000 - 1,300,000; Full time

Job summary

Wakefit Innovations is seeking a Process Excellence Lead to drive Lean initiatives across our HVLV manufacturing plant. You will champion process standardization, create robust SOPs and WI, and lead improvement projects from planning to closure.

Responsibilities include time studies, capacity analysis, and developing data dashboards to monitor OEE, yield, and cycle time. Opportunity to explore digital workflows and automation in a growing manufacturing setting.

Qualifications

• Experience applying Lean tools in HVLV manufacturing.
• Proven track record in driving continuous improvement.
• Ability to develop and standardize SOPs and WI.

Responsibilities

• Apply Lean principles to HVLV manufacturing to reduce losses.
• Develop and standardize SOPs, work instructions and process flows across plant value chain.
• Establish a documentation audit mechanism and drive improvements.
• Plan and execute Process Excellence (PEx) projects with milestones and benefits.
• Conduct time studies, capacity analysis and line balancing.
• Develop PEx dashboards and track performance metrics (OEE, yield).
• Identify opportunities to digitize workflows and data capture.
• Support automation feasibility studies and RDC improvements.
• Assist NPD with process mapping and capacity planning.

Skills

Lean principles

Kaizen

Process mapping

Data analysis

Documentation

Tools

PEx dashboards

Excel

Power BI

Job description

Role Purpose

Drive process improvement, standardization, productivity and operational excellence across the plant by
developing robust processes, managing improvement projects, strengthening documentation and implementing digital
solutions.

1. Process Excellence & Lean

• Understand and apply Lean principles by adapting Lean tools, systems and practices to the company’s High-Variety, Low-Volume (HVLV) manufacturing environment.
• Identify and eliminate process losses to improve productivity, flow, lead time, quality, cost and resource utilization.
• Drive Kaizen and continuous improvement initiatives across the plant.

2. SOP, Work Instructions & Process Documentation

• Develop and standardize SOPs, Work Instructions and process flows across the complete plant value chain —
  Order Taking ® JO Release ® Production Scheduling ® RM Issuance ® Production ® Stock Audit ® QC ® Packing ® Dispatch.
• Define process ownership, checkpoints, documentation requirements and standard formats.
• Ensure SOPs and Work Instructions reflect the actual and improved process.
• Maintain document revision and change control.
• Prepare and maintain the SOP/WI review schedule.

3. Documentation Audit & Improvement

• Establish a mechanism to audit process documentation for completeness, accuracy, timeliness and traceability.
• Identify documentation gaps and coordinate corrective actions with process owners.
• Continuously improve, simplify and standardize documentation.
• Identify opportunities for digitalization of documentation and process records.
• Prepare and maintain the documentation audit schedule.

4. PEx Project Planning & Execution

• Maintain a Process Excellence project pipeline covering ongoing, planned and future projects.
• Prioritize projects based on business impact, urgency and feasibility.
• Define project scope, milestones, timelines, owners and expected benefits.
• Track ongoing projects and ensure timely execution and closure.
• Monitor project benefits and ensure sustainability of improvements.

5. Productivity & Process Improvement

• Conduct time studies, process studies, line balancing and capacity analysis.
• Identify bottlenecks and improve manpower and machine utilization.
• Drive improvements in cycle time, throughput, yield, WIP and lead time.
• Support productivity improvement and capacity expansion initiatives.

6. Data & Performance Management

• Analyze operational data to identify improvement opportunities.
• Develop and maintain PEx dashboards and performance metrics.
• Track productivity, OEE, yield, rejection, rework, WIP, lead time and cost.
• Convert data-driven insights into improvement projects.

7. Digitalization

• Identify opportunities to digitize manual processes, documentation and data capture.
• Develop digital workflows, dashboards and tracking systems to improve visibility, accuracy and process control.
• Reduce manual data entry and duplicate documentation.
• Work with IT and process owners to implement and sustain digital solutions.

8. Automation – Optional

• Identify opportunities for process automation, semi-automation and machine/process improvements.
• Support feasibility studies, trials and implementation of automation projects.
• Evaluate automation opportunities based on productivity, quality, cost and ROI.

9. New Process / Product Support

Support NPD and new process implementation through process mapping, capacity study, manpower planning, cycle-time definition and SOP creation.

• Ensure new processes are standardized before implementation.