Senior Engineer – VSM & Material Flow

Texmoprecisioncastings; Coimbatore; On-site; INR 600,000 - 1,000,000; Full time

Benefits offered by this job

Remote Working

Medical Insurance

Life Insurance

Family Support and Care

Uniform

Paid Holiday

Subsidised Healthy Meals

Work-Life Balance

Annual Health Check-ups

Teamwork

Safety and Community Engagement

Open and Transparent Culture

Job summary

A leading manufacturing company in Coimbatore is looking for a Senior Engineer in Value Stream Mapping & Material Flow to enhance operational efficiency through continuous improvement projects. The role involves implementing lean methodologies, analyzing current processes, and collaborating with various teams to optimize material flow and inventory management. Candidates should have a relevant degree and 3-5 years of experience in lean manufacturing, along with strong analytical and communication skills.

Qualifications

• 3-5 years of experience in value stream mapping or lean manufacturing.
• Strong expertise in Pull system and JIT design.
• Experience executing Lean Improvement projects.

Responsibilities

• Conduct VSM sessions/workshops to improve processes.
• Design and deploy Kanban systems and establish FIFO lanes.
• Coordinate with teams to optimize inventory and implement VSIPs.

Skills

Analytical and problem-solving skills

Data collection and reporting

Lean tools familiarity (Kaizen, 5S)

Communication and collaboration skills

Independent work management

Education

Bachelor’s degree in Industrial Engineering

Bachelor’s degree in Production Engineering

Bachelor’s degree in Mechanical Engineering

Tools

AutoCAD

Power BI

Job description

Senior Engineer – Value Stream Mapping & Material Flow • Texmo Blank

Coimbatore, India • Manufacturing Operations

Purpose: The Sr. Engineer - Value Stream Mapping (VSM) & Material Flow will be responsible for driving continuous improvement initiatives by executing high impact VSM projects primarily on material flow for multiple value streams. This role will focus on implementing Single Piece Flow by designing, and sustaining pull-based production systems (Kanban, supermarket, JIT) to optimize flow, reduce inventory, and improve responsiveness to customer demand. Also tracking improvements through the generation and analysis of Value Stream Improvement Plans (VSIPs). The goal is to support the organization in achieving operational efficiency and process excellence.

Responsibilities

• Collect relevant data for each defined value stream.
• Conduct VSM sessions/workshops to analyze current state, identify inefficiencies/kaizen bursts, and create an entitlement and future state roadmap for improvements.
• Target Box score improvements and enable accomplishments.
• Analyze the generated Value Stream Improvement Plan (VSIPs) and prioritize for implementation.
• Work with cross-functional teams to ensure effective implementation of VSIPs with a focus on achieving Single Piece Flow.
• Design and deploy Kanban systems (card-based, e-Kanban, hybrid models).
• Establish supermarkets, FIFO lanes, and replenishment loops.
• Define inventory levels, buffer strategies, and replenishment signals.
• Align pull system with customer demand and takt time.
• Integrate pull system with ERP/MRP systems.
• Coordinate with planning, procurement and logistics teams to optimize inventory.
• Calculate and maintain Kanban quantities, reorder points and safety stock levels.
• Use data analytics for demand variability analysis, cycle time and lead time improvement and tracking.
• Continuously optimize the inventory towards reaching the single piece flow.
• Track the progress of VSIPs, ensuring the closure rate to meet the target of 80-90%.
• Track the Lead time and specific Pull system metrics.
• Collect data and generate weekly Box Scores for each value stream (6 Box Scores per week).
• Ensure that all metrics are up to date and accurately reflect the performance of each value stream.
• Document all improvements and changes made during the VSM process.
• Implement measures to sustain improvements over time, ensuring long-term efficiency and effectiveness.
• Work closely with cross-functional teams (Operations, Production, Quality, etc.) to implement changes and ensure alignment with business goals.
• Provide guidance and training on VSM principles and best practices to relevant stakeholders.

Education

• Bachelor’s degree in Industrial Engineering, Production Engineering, Mechanical Engineering

Experience

• Minimum of 3-5 years of experience in value stream mapping, process optimization, or lean manufacturing.
• Strong expertise in Pull system, Heijunka / load levelling and Just in Time design and implementation.

Skills

• Strong analytical and problem-solving skills.
• Proficient in data collection, analysis, and reporting.
• Familiarity with Lean tools and techniques (e.g., Kaizen, 5S, Value Stream Mapping).
• Excellent communication and collaboration skills.
• Ability to manage multiple priorities and work independently.

Lean Projects

• Experienced in executing Lean Improvement projects like Line Balancing & Cycle time optimization.
• AutoCAD or similar software for Layout change to improve material flow.
• Power BI (optional) for transactional flow improvement projects.

Benefits

• Remote Working
• Medical Insurance
• Life Insurance
• Family Support and Care
• Uniform
• Paid Holiday
• Subsidised Healthy Meals
• Work-Life Balance
• Annual Health Check-ups
• Teamwork
• Safety and Working for the Community
• Open and Transparent Culture