Senior Lean Manufacturing Specialist

Job Title: Senior Lean Manufacturing Specialist
Location: India
Experience: 7+ Years
Category: Lean Manufacturing

Job Summary:

We are seeking a highly skilled Senior Lean Manufacturing Specialist with a strong background in Kaizen, Six Sigma, and process optimization. The ideal candidate will have over 7 years of experience in implementing lean manufacturing principles, driving continuous improvement, and optimizing production processes. This role is responsible for identifying inefficiencies, leading Kaizen initiatives, and implementing Six Sigma methodologies to enhance productivity, reduce waste, and improve quality within the manufacturing environment.

Key Responsibilities:

1. Lean Manufacturing Implementation:
• Lead the implementation of lean manufacturing principles and practices across production processes to optimize workflow, reduce waste, and improve overall efficiency.
• Conduct assessments of existing production processes and identify areas for improvement using lean tools such as Value Stream Mapping (VSM), 5S, and Kanban.
• Champion the development and execution of standardized work procedures to improve consistency and reduce variability.
2. Kaizen Initiatives:
• Plan and execute Kaizen events to promote continuous improvement in production processes and reduce bottlenecks.
• Engage teams in Kaizen activities to foster a culture of continuous improvement and empower employees at all levels to contribute to process enhancement.
• Facilitate cross-functional collaboration to identify, prioritize, and solve operational issues.
3. Six Sigma Methodology:
• Utilize Six Sigma methodologies (DMAIC - Define, Measure, Analyze, Improve, Control) to drive quality improvements and reduce defects in the manufacturing processes.
• Apply statistical tools to analyze data and identify root causes of defects, inefficiencies, and variances.
• Develop and implement control plans to sustain improvements and ensure consistent quality output.
4. Process Optimization:
• Drive process optimization initiatives aimed at increasing productivity and reducing downtime while maintaining high standards of product quality.
• Analyze and improve workflows, cycle times, and throughput using data-driven insights.
• Implement tools such as time studies, capacity planning, and process mapping to identify opportunities for optimization.
5. Team Leadership and Training:
• Lead, train, and mentor cross-functional teams on lean manufacturing principles, Six Sigma tools, and continuous improvement methods.
• Foster a culture of teamwork, accountability, and problem-solving across departments to achieve operational excellence.
• Conduct workshops and training sessions to develop skills in lean methodologies and problem-solving techniques.
6. Performance Monitoring and Reporting:
• Track key performance indicators (KPIs) such as OEE (Overall Equipment Effectiveness), scrap rates, cycle time, and throughput to measure the impact of lean and Six Sigma initiatives.
• Prepare detailed reports and presentations for senior management, summarizing improvement efforts, progress, and outcomes.
• Use data analysis tools to monitor trends and identify areas requiring further attention.
7. Compliance and Best Practices:
• Ensure all process changes comply with regulatory standards and internal quality control practices.
• Stay updated with industry trends, new lean tools, and best practices to continuously enhance manufacturing efficiency.

Key Skills and Competencies:

• Lean Manufacturing: Expertise in applying lean principles to optimize production processes, eliminate waste, and increase efficiency.
• Kaizen: Proficiency in leading Kaizen events, fostering a culture of continuous improvement across teams.
• Six Sigma: Strong experience in applying Six Sigma methodologies (DMAIC) to improve quality and reduce defects.
• Process Optimization: Advanced skills in analyzing and optimizing production workflows, cycle times, and resource utilization.
• Data-Driven Decision Making: Ability to analyze data and use statistical tools to identify root causes and implement solutions.
• Problem Solving: Strong critical thinking and problem-solving skills to address production inefficiencies and quality issues.
• Team Leadership: Experience in mentoring, training, and leading cross-functional teams in lean and Six Sigma initiatives.
• Communication: Excellent communication skills to present findings, reports, and improvements to management and teams.

Qualifications:

• Bachelors degree in Industrial Engineering, Manufacturing Engineering, or a related field.
• 7+ years of experience in lean manufacturing, Six Sigma, and process optimization.
• Certified Lean Six Sigma Green Belt or Black Belt (preferred).
• Hands-on experience in driving continuous improvement initiatives in a manufacturing environment.