Role Purpose
The Senior Manager – Operational Excellence will lead strategic and continuous improvement initiatives across manufacturing, supply chain, and operations, with a strong focus on productivity, quality, cost optimization, capacity utilization, and operational excellence.
The role will be responsible for:
- Driving Lean, Six Sigma and TPM initiatives to improve OEE and reduce operational losses.
- Leading cross-functional improvement projects aligned with business OGSM (Objectives, Goals, Strategies & Measures).
- Developing and implementing the Continuous Improvement strategy, governance, and operating rhythm.
- Building problem-solving capabilities across teams and coaching operational leaders.
- Monitoring key operational KPIs and providing actionable insights to senior leadership.
- Leading Value Engineering, Capacity Optimization, Line Balancing, and Digital Transformation initiatives.
- Strengthening the overall culture of continuous improvement and data-driven decision-making across the plant.
Key Responsibilities
1. Daily Management System
- Lead and strengthen the Daily Management System – POS across the plant.
- Drive adherence to POS standards and routines across functions.
- Identify and close gaps emerging from POS audits, ensuring achievement of target scores.
- Support plant leadership in establishing a strong performance management and review cadence.
- Use daily management data to identify performance gaps and prioritize improvement opportunities.
2. Problem Solving & Continuous Improvement
- Lead Root Cause Analysis (RCA) initiatives and support production teams in improving OEE and eliminating chronic losses.
- Drive structured problem-solving using Lean Six Sigma, statistical tools, and data-driven methodologies.
- Train and coach operators and teams
- Develop an appreciation of the S&OP process and its linkage with operating hours, capacity utilization, and production planning.
- Lead and deliver cross-functional statistical improvement projects.
- Coach project managers and operational teams in structured problem-solving and project execution.
- Lead programs and manage portfolios of improvement initiatives across functions.
- Conduct Value Stream Mapping (VSM) and Line Balancing to identify and address chronic operational issues.
- Identify opportunities to improve productivity, reduce waste, optimize costs, and enhance quality.
3. Capability Development
- Mentor teams and build organizational capability in Continuous Improvement, Lean Six Sigma, and structured problem-solving.
- Develop and execute capability-building programs through the LSS Calendar cycle.
- Conduct skill assessments of operators and identify capability gaps.
- Lead targeted improvement and training programs to close identified capability gaps.
- Build a strong pipeline of internal CI champions and problem-solving practitioners.
4. Capacity Planning & Budgeting
- Develop a strong understanding of Capacity Planning and OEE Loss Trees and their linkage to short-term and long-term factory budgeting.
- Support capacity optimization initiatives based on demand, operating hours, OEE, and available resources.
- Develop an understanding of and contribute to budgeting processes related to:
- Energy
- Labour
- Maintenance
- Repairs
- Operational efficiency
- Identify opportunities to improve cost efficiency through productivity and operational improvement initiatives.
- Work collaboratively with multiple departments and functions to align operational improvement priorities with business requirements.
5. Digitization & Industry 4.0
- Lead Industry 4.0 and manufacturing digitization initiatives across the plant.
- Develop a strong understanding of the automation pyramid and its application within manufacturing environments.
- Identify opportunities to digitize manual processes, reports, and performance-monitoring systems.
- Lead small- to medium-scale digitization projects related to manufacturing reporting and operational performance.
- Leverage data and digital tools to improve visibility, decision-making, and operational efficiency.
Qualifications & Certifications
Educational Qualifications
- Bachelor’s degree in Engineering or a related technical discipline.
- Master’s degree preferred.
Certifications
- TPM Expert / Black Belt Certification from a recognized institution/body such as ASQ, JIPM, or equivalent.
- Lean Six Sigma certification preferred.
Experience
- 8–12 years of overall professional experience.
- Minimum 4–5 years of experience in FMCG / manufacturing environments, preferably in an Operational Excellence / Continuous Improvement role.
- Proven experience in leading Continuous Improvement programs and cross-functional teams.
- Demonstrated experience in driving measurable improvements in OEE, productivity, cost, quality, capacity utilization, and operational performance.
- Experience in leading multiple improvement projects/programs simultaneously.