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Department Head Manufacturing Excellence
FA Home
posted 17d ago
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Job Description
The role of a Department Head in Manufacturing Excellence related to Industrial Engineering is vital. This position aims to drive operational efficiency, quality improvement, and cost reduction while ensuring safety and maintaining industry standards. Here are the key responsibilities across various areas:
- Factory Floor Layout Optimization: Design and modify the Factory production floor layout to improve workflow efficiency, reduce material handling time, and optimize space utilization. Aim for a logical flow from raw materials to finished goods to minimize bottlenecks w.r.t pointers related with Industrial Engineering.
- Standard Operating Procedures (SOPs): Ensure clear SOPs are established for all critical operations and are followed consistently. Regularly review and update SOPs to incorporate best practices and address changing requirements.
- Cycle Time Reduction: Evaluate and optimize each stage of the manufacturing process to reduce cycle times (SAM) without compromising quality. Focus on bottlenecks and areas of high variation.
- Root Cause Analysis: Establish procedures for identifying the root causes of machine failures and implement corrective actions. Track machine performance metrics and develop KPIs for maintenance effectiveness.
- Preventive Maintenance Strategy: Develop and implement a preventive maintenance plan to minimize downtime and extend machine lifespan. Collaborate with maintenance teams to establish schedules based on machine criticality and usage patterns.
- Drive Continuous Improvement: Develop and implement programs like Lean Manufacturing, Six Sigma, or Total Productive Maintenance (TPM) to foster continuous improvement across production and operations.
- Cost Optimization: Lead initiatives focused on reducing waste, minimizing defects, and improving efficiency to lower production costs and enhance profitability.
- Optimize Production Processes: Identify bottlenecks and inefficiencies in production processes and implement corrective measures. Ensure that manufacturing processes are aligned with best practices.
- Cross-Functional Team Collaboration: Coordinate with cross-functional teams (production, planning, logistics, quality) to streamline order-to-delivery cycles. Facilitate regular team meetings to align on production schedules and minimize delays. Work closely with the Quality Control (QC) team to implement strict quality standards.
- Data-Driven Decision Making: Implement and leverage data collection systems for real-time monitoring and analysis of production data to make informed decisions. Also sharing Timely MIS Reports to related Stakeholders and Management.
- Benchmarking and Best Practices: Continuously benchmark internal practices against industry standards and competitor practices, implementing best practices to stay ahead in efficiency and productivity.
- Digital Transformation and Smart Manufacturing: Drive digitalization in manufacturing by implementing software solutions for inventory management, predictive maintenance, and production scheduling. Lead initiatives to digitize processes, adopting Industry 4.0 technologies such as IoT, data analytics, and predictive maintenance tools to enhance productivity and predict equipment failures.
- ESG/Sustainability Initiatives: Lead efforts to adopt eco-friendly manufacturing processes, reduce emissions, and improve waste management in line with global sustainability trends and export compliance.
- Team Development: Build and mentor a high-performing team within the Manufacturing Excellence department, ensuring that staff are trained in lean principles, quality standards, and industry best practices.
- Training Programs: Develop and implement training programs on quality management, process improvement, and other relevant topics to enhance skill sets across the production workforce. Facilitate training and upskilling of operators and technicians to improve productivity and reduce reliance on specific individuals.
Desired Qualification & Competencies:
- A bachelor s degree in Industrial Engineering, Mechanical Engineering, Textile Engineering, or a related field is essential. A master s degree in Manufacturing, Industrial Engineering, or Business Administration (MBA) is often preferred.
- Certifications in Lean Six Sigma, Certified Manufacturing Engineer shall be a plus
Experience:
- At least 20+ years of experience in Industrial Engineering/ Manufacturing Excellence roles, with a minimum of 10 years in a leadership position.
- Proven track record of implementing Lean, Six Sigma, or other continuous improvement initiatives with measurable outcomes (e.g., reduced lead times, cost savings).
- Experience leading organizational change, particularly in adopting new technologies, process improvements, and safety practices on the shop floor.
- Deep understanding of preventive, predictive, and corrective maintenance practices. Knowledge of automation systems, Industry 4.0 technologies, and predictive maintenance tools (e.g., IoT sensors)
- Knowledge of sustainable manufacturing practices and commitment to reducing environmental impact through efficient resource usage and waste management
Employment Type: Full Time, Permanent
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Strict timing
Monday to Saturday
No travel
Day Shift
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