Manufacturing Process Improvement Lead

TICA CLIMATE SOLUTIONS MALAYSIA SDN BHD; Nilai; On-site; MYR 180,000 - 240,000; Full time

Job summary

TICA Climate Solutions Malaysia Sdn. Bhd. seeks a Process Manager to lead Lean manufacturing initiatives across our high-tech HVAC production.

You will drive standardised processes, cut waste, and improve productivity, collaborating with R&D, QA/QC, Maintenance and Supply Chain to ensure stable operations. The role requires 5–8 years in manufacturing/process engineering, with strong Lean, Kaizen, 5S and Value Stream Mapping expertise.

Qualifications

• Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering or a related engineering discipline.
• Five to eight years of relevant experience in manufacturing or process engineering.
• At least three years of experience in a supervisory or managerial role.
• Proven experience implementing Lean Manufacturing and continuous improvement projects.
• Experience managing manufacturing processes, production efficiency and cost optimisation.
• Strong knowledge of Lean Manufacturing, Kaizen, 5S and Value Stream Mapping.
• Practical understanding of 4M Management and change control.
• Strong knowledge of the 8 Wastes and waste elimination techniques.
• Proficiency in process optimisation, line balancing, cycle time, takt time and Overall Equipment Effectiveness.
• Strong knowledge of root cause analysis, 5 Why, Fishbone Diagram and 8D.
• Familiarity with Process FMEA, Control Plans, Statistical Process Control and ISO 9001 quality management systems.
• Proficiency in Microsoft Excel and data analysis.
• Knowledge of Power BI is an advantage.

Responsibilities

• Lead the implementation of Lean Manufacturing principles and continuous improvement initiatives across manufacturing operations.
• Identify, analyse and eliminate the 8 Wastes: Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects and Skills underutilisation.
• Drive Kaizen, 5S, Value Stream Mapping, Standard Work and other Lean improvement activities.
• Improve production flow, line balancing, cycle time, takt time and Overall Equipment Effectiveness.
• Identify process bottlenecks and implement effective countermeasures to improve productivity and operational efficiency.
• Establish and maintain effective 4M Management covering Man, Machine, Material and Method to ensure process stability.
• Monitor and evaluate process changes involving manpower, machinery, materials and production methods.
• Establish process control standards and ensure compliance with approved manufacturing procedures.
• Lead 4M change assessments and ensure appropriate validation before implementing process changes.
• Identify process risks and implement preventive actions to minimise production disruptions and quality issues.
• Review manufacturing processes and identify opportunities for productivity improvement and cost reduction.
• Develop and optimise production layouts, workflows, tooling, jigs and fixtures.
• Improve manpower utilisation, machine capacity, production cycle time and material consumption.
• Establish and maintain standardised work procedures and process control standards.
• Collaborate with Production, R&D, QA/QC and Maintenance teams to improve process efficiency and product manufacturability.
• Support new product introduction, process validation, trial runs and mass production ramp-up.
• Lead structured root cause analysis using 5 Why, Fishbone Diagram, 8D and other problem-solving tools.
• Investigate recurring production defects, process abnormalities and manufacturing inefficiencies.
• Collaborate with relevant departments to implement corrective and preventive actions.
• Establish Process FMEA, Control Plans and process validation requirements where applicable.
• Monitor process performance and ensure improvement actions are effective and sustainable.
• Drive initiatives to reduce manufacturing costs, material wastage, labour costs and energy consumption.
• Establish and monitor key process performance indicators, including production efficiency, labour productivity, cycle time, takt time, Overall Equipment Effectiveness, First Pass Yield, scrap and rework rate, and manufacturing cost per unit.
• Lead productivity improvement projects and deliver measurable operational expenditure savings.
• Prepare regular performance reports and present improvement results to management.
• Lead, coach and develop the Process Engineering team.
• Establish technical competency and development plans for process engineers and technicians.
• Promote a Lean and continuous improvement culture across production teams.
• Work closely with Production, QA/QC, R&D, Maintenance, Warehouse and Supply Chain teams to achieve operational targets.

Skills

Lean Manufacturing

Kaizen

5S

Value Stream Mapping

Root Cause Analysis

4M Management

Process Optimisation

Statistical Process Control

ISO 9001 Quality Management

Power BI (adv)

Education

Bachelor's Degree in Mechanical Engineering

Tools

Excel

Power BI

Job description

TICA Climate Solutions Malaysia Sdn. Bhd. seeks a Process Manager to lead Lean manufacturing initiatives across our high-tech HVAC production.

You will drive standardised processes, cut waste, and improve productivity, collaborating with R&D, QA/QC, Maintenance and Supply Chain to ensure stable operations. The role requires 5–8 years in manufacturing/process engineering, with strong Lean, Kaizen, 5S and Value Stream Mapping expertise.