Process Excellence Manager

Manager – Process Excellence

Department: Process ExcellenceReporting To: Head – Process Excellence

Location: HosurRole purpose:Drive process improvement, standardization, productivity and operational excellence across the plant by developing robust processes, managing improvement projects, strengthening documentation and implementing digital solutions.Key responsibilities:1.

Process excellence & lean

• Understand and apply Lean principles by adapting Lean tools, systems and practices to the company's High-Variety, Low-Volume (HVLV) manufacturing environment.
• Identify and eliminate process losses to improve productivity, flow, lead time, quality, cost and resource utilization.
• Drive Kaizen and continuous improvement initiatives across the plant.2. SOP, work instructions & process documentation
• Develop and standardize SOPs, Work Instructions and process flows across the complete plant value chain: Order Taking > JO Release > Production Scheduling > RM Issuance > Production > Stock Audit > QC > Packing > Dispatch.
• Define process ownership, checkpoints, documentation requirements and standard formats.
• Ensure SOPs and Work Instructions reflect the actual and improved process.
• Maintain document revision and change control.
• Prepare and maintain the SOP/WI review schedule.3. Documentation audit & improvement
• Establish a mechanism to audit process documentation for completeness, accuracy, timeliness and traceability.
• Identify documentation gaps and coordinate corrective actions with process owners.
• Continuously improve, simplify and standardize documentation.
• Identify opportunities for digitalization of documentation and process records.
• Prepare and maintain the documentation audit schedule.4. PEx project planning & execution
• Maintain a Process Excellence project pipeline covering ongoing, planned and future projects.
• Prioritize projects based on business impact, urgency and feasibility.
• Define project scope, milestones, timelines, owners and expected benefits.
• Track ongoing projects and ensure timely execution and closure.
• Monitor project benefits and ensure sustainability of improvements.5. Productivity & process improvement
• Conduct time studies, process studies, line balancing and capacity analysis.
• Identify bottlenecks and improve manpower and machine utilization.
• Drive improvements in cycle time, throughput, yield, WIP and lead time.
• Support productivity improvement and capacity expansion initiatives.6. Data & performance management
• Analyze operational data to identify improvement opportunities.
• Develop and maintain PEx dashboards and performance metrics.
• Track productivity, OEE, yield, rejection, rework, WIP, lead time and cost.
• Convert data-driven insights into improvement projects.7. Digitalization
• Identify opportunities to digitize manual processes, documentation and data capture.
• Develop digital workflows, dashboards and tracking systems to improve visibility, accuracy and process control.
• Reduce manual data entry and duplicate documentation.
• Work with IT and process owners to implement and sustain digital solutions.8. Automation
• Identify opportunities for process automation, semi-automation and machine/process improvements.
• Support feasibility studies, trials and implementation of automation projects.
• Evaluate automation opportunities based on productivity, quality, cost and ROI.9. New process / product support
• Support NPD and new process implementation through process mapping, capacity study, manpower planning, cycle-time definition and SOP creation.
• Ensure new processes are standardized before implementation.Key skills:
• Lean Manufacturing & Continuous Improvement
• Industrial Engineering
• Process Mapping & Standardization
• Time & Motion Study
• Capacity & Productivity Analysis
• Project Management
• Root Cause Analysis
• Data Analysis
• SOP & Work Instruction Development
• Documentation Management
• Digitalization (Mandatory)
• Automation (Optional)
• Change Management (Optional)Key KPIs:
• Productivity Improvement
• Cost Savings
• Cycle-Time Reduction
• Lead-Time Reduction
• Yield Improvement
• OEE Improvement
• WIP Reduction
• PEx Project Completion
• Project Benefits Realized
• SOP/WI Completion & Compliance
• Documentation Audit Score
• Documentation Improvement / Digitalization InitiativesQualification & experience:
• Bachelor's degree in mechanical / industrial / production engineering or equivalent.
• 3–8 years of experience in Process Excellence, Industrial Engineering, Manufacturing Excellence or Operations.
• Strong manufacturing shop-floor exposure.
• Experience in Lean, Kaizen, process improvement and project execution.
• Experience in High-Variety, Low-Volume manufacturing will be an advantage.Core expectation:The role is expected to understand the existing operating system, identify gaps, adapt Lean and Process Excellence practices to the company's HVLV environment, standardize improved processes, strengthen documentation, drive digitalization and maintain a continuous pipeline of improvement projects.