Senior Operational Excellence Engineer

Senior Engineer – Operational Excellence Role Overview: - We are seeking a highly motivated Industrial Engineer to join our Operational Excellence (OPEX) team for our Pipe Manufacturing Division. This role will be responsible for driving productivity improvements, cost optimization, process engineering, Lean implementation, and digital transformation across various manufacturing lines. The ideal candidate should have hands‑on experience in manufacturing operations along with strong analytical skills and a solid foundation in Industrial Engineering, Lean tools, and Work Study . Key Responsibilities Conduct detailed Time Studies using stopwatch and PMTS (MOST/MTM) to determine Standard Times. Establish Standard Operating Cycles , manpower norms, and productivity baselines. Apply Method Study to optimize labor, motion, and process flow. Perform Line Balancing for extrusion lines, socketing lines, threading stations, packing operations, etc. Analyze and minimize non-value-added activities on the shop floor. Support capacity planning, manpower modelling, and machine loading plans. Implement Lean methodologies such as: 5S, Kaizen, Poka-Yoke, Kanban, Andon, Jidoka, Visual Controls SMED to reduce die/tool changeover time in extrusion Value Stream Mapping (VSM) – Current State & Future State Standard Work creation and audits Drive waste reduction projects focusing on defects, waiting, movement, overprocessing, inventory, and overproduction. Lead shop-floor improvement activities, conducting Gemba walks , Kaizen blitz, and cross-functional workshops. Capture and analyze Overall Equipment Effectiveness (OEE) across production lines. Conduct Six Big Losses analysis and identify chronic issues (Breakdown, Speed Loss, Idling, Defects). Work closely with Maintenance to minimize breakdowns and micro stoppages. Develop daily/weekly/monthly loss reports and implement action plans to reduce performance and quality losses. Collaborate with Production & Quality teams to improve dimensional consistency, reduce ovality, thickness variation, and melt defects. Conduct trials for new dies, calibrators, and raw material combinations. Drive FMEA , identify high-risk processes, and implement CAPA. Support process validation, SOP creation, and continuous standardization across shifts. Build and maintain dashboards for OEE, downtime, energy consumption, yield, and scrap trends using Excel / Power BI & Python – Program Based Excel Automation . Collect, analyze, and interpret production data to identify improvement opportunities. Conduct Cost-per-Kg analysis for products. Support initiatives related to: Material yield improvement, Energy reduction (kWh/ton) , anpower optimization, Changeover time reduction Validate and document project benefits in line with OPEX financial goals. Requirement: B.E./B.Tech in Industrial Engineering, Mechanical, Production Engineering (Mandatory) Lean Six Sigma Yellow/Green Belt preferred Additional coursework in Lean, TPM, or OPEX is an advantage 1–2 years in manufacturing, preferably in manufacturing , polymer processing, or continuous production lines Experience in Industrial Engineering OR Operational Excellence department is required Excel (Advanced), Power BI dashboards, Basic Python/R (optional), AutoCAD for layout design (preferred) Time Study (Stopwatch, MOST/MTM), Work Measurement, DILO, VA, NVA Analysis, Workload & manpower modeling, Line balancing (continuous & batch processes), Plant layout improvement and workflow optimization, Ergonomics and workstation design principles. 5S implementation & audit readiness, Kaizen / CI project execution, VSM (Value Stream Mapping), SMED for quick changeovers, Kanban & Pull systems, Poka-Yoke design & implementation, Root Cause Analysis (5 Why, Fishbone, Pareto) Behavioral Competencies Strong analytical and problem-solving ability Proactive, structured, and detail-oriented approach Good communication for cross-functional collaboration Ability to lead shop-floor teams and drive change Hands-on, shop-floor oriented mindset High sense of ownership and accountability Experience Level Senior Level