Operational Excellence - AGM/DGM

Operational Excellence (AGM/DGM) Bull Machines Pvt Ltd

Position Title: AGM/DGM Operational Excellence

Location: Coimbatore

Department: Operations Excellence

Industry: Construction Equipment Manufacturing

Job Summary:

Bull Machines Pvt Ltd, a leading manufacturer of construction and heavy machinery, is looking for a AGM/DGM for Operational Excellence. The AGM/DGM will oversee and optimize operational processes, enhance manufacturing efficiency, ensure product quality, and lead initiatives across product design, production, and supply chain management. The role requires advanced technical expertise in construction equipment manufacturing and a deep understanding of process improvement methodologies, quality assurance, and performance metrics.

Key Responsibilities:

1. Operational Strategy & Leadership:
• Formulate and implement operational excellence strategies focusing on manufacturing processes such as assembly lines, welding, material handling, and machine calibration for construction equipment.
• Integrate advanced technologies (e.g., automation, robotics, IoT) in operational processes to improve throughput, product quality, and reduce cycle times in production.
• Manage production schedules and resource allocation to ensure seamless operations from raw material sourcing to final product delivery.
2. Process Improvement & Lean Management:
• Spearhead the adoption of Lean Manufacturing principles, including Kaizen, Just-in-Time (JIT), and Total Productive Maintenance (TPM), to minimize waste and enhance productivity.
• Implement Six Sigma methodologies to improve process control and reduce variability in production.
• Perform Value Stream Mapping (VSM) to identify and eliminate inefficiencies in the flow of materials, components, and products.
• Develop and implement 5S methodologies (Sort, Set in order, Shine, Standardize, and Sustain) to ensure high levels of organization and cleanliness on the shop floor.
3. Cross-Functional Collaboration:
• Collaborate with R&D and design teams to implement engineering changes and ensure that design modifications are manufacturable, cost-effective, and scalable in production.
• Coordinate with the supply chain team to optimize inventory levels, reduce lead times, and ensure timely availability of critical components like engines, hydraulics, and transmission systems for machinery production.
• Work with the quality control team to establish testing protocols for high-stress components (e.g., hydraulic pumps, undercarriages, engine blocks) and ensure compliance with international standards (e.g., ISO 9001, CE certifications).
4. Performance Monitoring & Reporting:
• Implement real-time monitoring systems (e.g., SCADA, MES) to track production processes, measure downtime, and identify bottlenecks.
• Develop operational dashboards that display key metrics such as OEE (Overall Equipment Efficiency), MTTR (Mean Time to Repair), MTBF (Mean Time between Failures), and Cycle Time for critical equipment and processes.
• Provide detailed reports on performance and improvement initiatives to senior management, with actionable insights and strategic recommendations.
• Implement and utilize advanced data analytics and Manufacturing Execution Systems (MES) to track production performance, equipment uptime, and process deviations in real time.
5. Quality Assurance & Compliance:
• Oversee quality management systems for welding, machining, painting, and final assembly processes of construction equipment.
• Ensure compliance with industry safety standards (e.g., OSHA, EN474) and environmental regulations related to the manufacturing of heavy equipment.
• Lead the implementation of Root Cause Analysis (RCA) and Failure Mode and Effects Analysis (FMEA) techniques to prevent defects and improve product reliability.
6. Cost Management & Budgeting:
• Develop detailed budgets for operational excellence initiatives, with a focus on improving cost efficiency in labor, materials, and overhead.
• Drive cost-reduction strategies in the procurement and production of components such as engines, hydraulic systems, and chassis by leveraging supplier partnerships, economies of scale, and alternative sourcing options.
7. Change Management & Culture Building:
• Lead change management initiatives by guiding teams through the adoption of new technologies, production methods, or organizational restructuring.
• Encourage innovation by supporting the implementation of Industry 4.0 solutions (e.g., predictive maintenance, digital twins, and smart manufacturing systems) to advance production capabilities.
• Foster a culture of continuous improvement through employee engagement programs like Gemba Walks and Kaizen events, promoting feedback from operators to enhance processes.
8. Safety & Sustainability:
• Ensure that safety standards are followed during manufacturing processes, including heavy machinery handling, welding operations, and assembly line activities.
• Advocate for the use of eco-friendly materials and manufacturing processes, such as energy-efficient machinery, recycling of scrap materials, and reduced emissions during manufacturing.
• Promote sustainable practices across the entire life cycle of construction equipment, from design to decommissioning, ensuring compliance with global sustainability goals.

Qualifications & Skills:

• Education:
• Bachelors degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or a related field. Relevant certifications in Lean or Six Sigma are added advantage.
• Experience:
• 15- 20 years of experience in operational management within the manufacturing or construction equipment industry, with a focus on production optimization, quality control, and operational excellence.
• Proven success in leading large teams and driving improvements in heavy equipment manufacturing processes, such as welding, assembly, and machining of mechanical, hydraulic, and electronic systems.
• Experience with implementing advanced manufacturing technologies (e.g., CNC machining, robotics, automated assembly lines).
• Technical Skills:
• Expertise in Lean Manufacturing, Six Sigma (Black Belt or Green Belt), TPM, and Kaizen methodologies.
• Familiarity with smart manufacturing, predictive analytics, and machine learning for process optimization.
• Proficiency in Enterprise Resource Planning (ERP) systems (e.g., SAP).
• Experience with 3D modeling software (e.g., Creo, AutoCAD ) for process design and optimization.
• Strong understanding of ISO 9001, ISO 14001, and other quality management and environmental certifications.

Key Personal Attributes:

• Excellent problem-solving skills, with the ability to troubleshoot complex issues in manufacturing processes.
• Strong leadership capabilities to drive cross-functional teams toward achieving operational excellence.
• Data-driven decision-maker with the ability to analyze complex production data and translate insights into actionable strategies.
• Adaptability to changing industry trends and emerging technologies.

What We Offer:

• Competitive salary and benefits package.
• Opportunity to work with a leading company in the construction equipment industry.
• Career growth opportunities in a dynamic and rapidly evolving industry.
• A supportive and innovative work environment.

To apply, please send your updated resume and a cover letter detailing your relevant experience and qualifications to recruiter@bullmachine.com .

Bull Machines Pvt Ltd is an equal opportunity employer. We value diversity and are committed to creating an inclusive environment for all employees.