Job Purpose
Lead and drive the company’s continuous improvement agenda by planning, implementing, and sustaining Lean Manufacturing systems, executing Kaizen projects, and developing strategic suppliers to meet world-class manufacturing standards. Ensure operational excellence, waste reduction, and enhanced supply chain performance while fostering a culture of problem-solving and innovation.
Key Responsibilities1. Kaizen & Continuous Improvement Projects
- Identify, plan, and execute Kaizen events targeting cost reduction, productivity enhancement, quality improvement, and lead-time reduction.
- Facilitate cross-functional workshops to address bottlenecks, process variations, and waste (Muda).
- Track and report performance improvements using measurable KPIs (OEE, scrap rate, changeover time, etc.).
- Promote employee engagement in continuous improvement through suggestion systems and recognition programs.
2. Lean Manufacturing Implementation
- Deploy Lean tools such as 5S, SMED, Kanban, Value Stream Mapping (VSM), and Standard Work across production areas.
- Integrate Lean principles into the company’s operational strategy and daily management systems.
- Train and mentor production, quality, and maintenance teams on Lean concepts and practical application.
- Audit and sustain Lean practices through regular Gemba walks and KPI reviews.
3. Supplier Development & Quality Improvement
- Evaluate and categorize suppliers based on performance, quality, delivery, and cost metrics.
- Work closely with procurement to develop and implement supplier improvement plans.
- Conduct supplier audits to ensure compliance with company specifications and quality standards.
- Collaborate with suppliers to adopt Lean practices and improve consistency of raw materials.
4. Data-Driven Decision Making
- Establish a continuous improvement dashboard with operational, quality, and supplier KPIs.
- Analyze production and supply chain data to identify improvement opportunities.
- Lead root cause analysis (RCA) and implement corrective and preventive actions (CAPA).
5. Culture & Capability Building
- Act as the change agent to embed a culture of continuous improvement across all departments.
- Develop internal CI capability through structured training programs.
- Recognize and celebrate improvement successes to motivate teams.
- Bachelor’s degree in Industrial Engineering, Mechanical Engineering, or related field (Master’s degree or Lean Six Sigma Black Belt certification preferred).Experience:- 8–12 years in manufacturing, with at least 3 years in packaging or corrugated carton production.- Proven track record in Lean Manufacturing deployment, Kaizen facilitation, and supplier quality improvement.Technical Skills:- Lean Manufacturing methodologies (5S, SMED, TPM, VSM, Kanban).- Kaizen event planning & facilitation.- Supplier evaluation & development.- Data analysis tools (Excel, Power BI, Minitab, or equivalent).- Strong understanding of corrugated board production processes, raw materials, and quality standards.Soft Skills:- Excellent leadership and coaching abilities.- Strong analytical and problem-solving skills.- Effective communicator with cross-functional teams and suppliers.- Change management and conflict resolution capability.KPIs & Success Metrics- % Improvement in OEE and productivity.- Reduction in scrap/waste percentage.- Lead-time reduction in order fulfillment.- Supplier on-time delivery and quality score improvement.- Number and impact of implemented Kaizen initiatives.- Employee participation rate in CI programs.