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Senior Engineer – Operational Excellence

Aliaxis
Bengaluru, IND
Full-time
Senior · 1–2 years experience
Onsite
Discovered 3 weeks ago
autocadpower-bipython

Full Job Posting

Key Responsibilities

  • Conduct detailed Time Studies using stopwatch and PMTS (MOST/MTM) to determine Standard Times.
  • Establish Standard Operating Cycles, manpower norms, and productivity baselines.
  • Apply Method Study to optimize labor, motion, and process flow.
  • Perform Line Balancing for extrusion lines, socketing lines, threading stations, packing operations, etc.
  • Analyze and minimize non-value-added activities on the shop floor.
  • Support capacity planning, manpower modelling, and machine loading plans.
  • Implement Lean methodologies such as:
  • 5S, Kaizen, Poka-Yoke, Kanban, Andon, Jidoka, Visual Controls
  • SMED to reduce die/tool changeover time in extrusion
  • Value Stream Mapping (VSM) – Current State & Future State
  • Standard Work creation and audits
  • Drive waste reduction projects focusing on defects, waiting, movement, overprocessing, inventory, and overproduction.
  • Lead shop-floor improvement activities, conducting Gemba walks, Kaizen blitz, and cross-functional workshops.
  • Capture and analyze Overall Equipment Effectiveness (OEE) across production lines.
  • Conduct Six Big Losses analysis and identify chronic issues (Breakdown, Speed Loss, Idling, Defects).
  • Work closely with Maintenance to minimize breakdowns and micro stoppages.
  • Develop daily/weekly/monthly loss reports and implement action plans to reduce performance and quality losses.
  • Collaborate with Production & Quality teams to improve dimensional consistency, reduce ovality, thickness variation, and melt defects.
  • Conduct trials for new dies, calibrators, and raw material combinations.
  • Drive FMEA, identify high-risk processes, and implement CAPA.
  • Support process validation, SOP creation, and continuous standardization across shifts.
  • Build and maintain dashboards for OEE, downtime, energy consumption, yield, and scrap trends using Excel / Power BI & Python – Program Based Excel Automation.
  • Collect, analyze, and interpret production data to identify improvement opportunities.
  • Conduct Cost-per-Kg analysis for products.
  • Support initiatives related to: Material yield improvement, Energy reduction (kWh/ton), anpower optimization, Changeover time reduction
  • Validate and document project benefits in line with OPEX financial goals.
  • Requirement:
  • B.E./B.Tech in Industrial Engineering, Mechanical, Production Engineering (Mandatory)
  • Lean Six Sigma Yellow/Green Belt preferred
  • Additional coursework in Lean, TPM, or OPEX is an advantage
  • 1–2 years in manufacturing, preferably in manufacturing, polymer processing, or continuous production lines
  • Experience in Industrial Engineering OR Operational Excellence department is required
  • Excel (Advanced), Power BI dashboards, Basic Python/R (optional), AutoCAD for layout design (preferred)
  • Time Study (Stopwatch, MOST/MTM), Work Measurement, DILO, VA, NVA Analysis, Workload & manpower modeling, Line balancing (continuous & batch processes), Plant layout improvement and workflow optimization, Ergonomics and workstation design principles.
  • 5S implementation & audit readiness, Kaizen / CI project execution, VSM (Value Stream Mapping), SMED for quick changeovers, Kanban & Pull systems, Poka-Yoke design & implementation, Root Cause Analysis (5 Why, Fishbone, Pareto)
  • Behavioral Competencies
  • Strong analytical and problem-solving ability
  • Proactive, structured, and detail-oriented approach
  • Good communication for cross-functional collaboration
  • Ability to lead shop-floor teams and drive change
  • Hands-on, shop-floor oriented mindset
  • High sense of ownership and accountability

Qualifications

  • B.E./B.Tech in Industrial Engineering, Mechanical, Production Engineering (Mandatory)
  • Lean Six Sigma Yellow/Green Belt preferred
  • Additional coursework in Lean, TPM, or OPEX is an advantage
  • 1–2 years in manufacturing, preferably in manufacturing, polymer processing, or continuous production lines
  • Experience in Industrial Engineering OR Operational Excellence department is required
  • Excel (Advanced), Power BI dashboards, Basic Python/R (optional), AutoCAD for layout design (preferred)
  • Time Study (Stopwatch, MOST/MTM), Work Measurement, DILO, VA, NVA Analysis, Workload & manpower modeling, Line balancing (continuous & batch processes), Plant layout improvement and workflow optimization, Ergonomics and workstation design principles.
  • 5S implementation & audit readiness, Kaizen / CI project execution, VSM (Value Stream Mapping), SMED for quick changeovers, Kanban & Pull systems, Poka-Yoke design & implementation, Root Cause Analysis (5 Why, Fishbone, Pareto)
  • Behavioral Competencies
  • Strong analytical and problem-solving ability
  • Proactive, structured, and detail-oriented approach
  • Good communication for cross-functional collaboration
  • Ability to lead shop-floor teams and drive change
  • Hands-on, shop-floor oriented mindset
  • High sense of ownership and accountability

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