Team Leader - COE

India
Permanent
Full-time

15 days ago

DivisionDepartmentSub Department 1Job PurposeDrive manufacturing excellence initiatives to increase throughput of manufacturing sites by periodical interactions and involvements at functional areas and hence provide a support platform of operational efficiency to achieve quality standards and production targetsKey Accountabilities (1/6)Monitor sustainability of performance dialogue in section/ department to check plan vs. actual production and find root cause if there is any delay

Monitor Shift PD and Section PD to check sustainability of review mechanism
Monitor daily department head PD and update the action items generated during discussion
Track action items and review open items on daily basis with the concerned person
Conduct production review meet monthly with unit head vs. department head to review all production KPIs
Monitor PDCA (Plan do check and act) system continuously
Ensure maximum utilization of machine in working shift by reviewing the under-utilization of the machine and mentioning the same while tracking action item
Focus on reduction of waste, variability and inflexibility of 3M (Man, material, method) to increase value added portion of work, efficiency of people, profitability and customer satisfaction respectively
Provide support to department for audit readiness by being compliant

Key Accountabilities (2/6)Monitor OEE (Overall Equipment Effectiveness) and efficiency of area/ machine and identify major loss to focus on continue improvement

Monitor Daily OEE of bottleneck machine to measure the losses during process
Review monthly the OEE data of all machine and area and ensure to minimize the major loss (Speed loss/ breakdown loss/ unplanned loss/ planned loss/ changeover loss)
Reduce the cost, effort, and frustration required to perform the procedure or changeover by streamlined procedures provide to many related areas of the production
Track monthly changeover time of machine/ area to maintain/ sustain compared to standard time
Monitor the existing process of production and analyse the relevant data to standardized process cycle time
Prepare and monitor value stream mapping of runner products
Conduct Hourly planning of bottleneck machine to reduce down time loss
Conduct time and motion study of man/ material to optimize the productivity time and simplify the process
Conduct DILO Analysis to increase the personal efficiency (OPE)
Maintain the efficiency benchmark of each machine/ area by tracking and reviewing machine/ area monthly

Key Accountabilities (3/6)Monitor CapEx and OpEx and create awareness about frugality to ensure cost reduction

Review monthly the operating and manpower expenses and compare expenses with historic data
Conduct frugality workshop session on cost saving to create awareness among the people for frugal mind set
Distribute pool manpower from non-working area to working area to reduce associates cost

Key Accountabilities (4/6)Conduct Kaizen implementation session for continue improvement

Conduct idea generation and evaluation session frequently w.r.t. to quality/ cost/ productivity/ process/ safety etc.
Gather the ideas generated from departments and sections and update status
Implement 5 “S” framework and check for sustainability in departments
Identify and propose monthly the person with the best idea to be awarded as the performer of the month
Conduct cross-functional brain-storming and problem solving session on root causes of variance

Monitor yield of runner products to focus on continue improvements & Sustainability

Monitor the yield of runner products to ensure yield above the baseline
Perform rejection analysis and provide support to production team by identifying the source of rejection and providing alternatives to increase the yield of products

Key Accountabilities (5/6)Prepare and maintain Dashboard to track sustainability progress

Prepare daily report of unit by collecting the data from all department
Prepare weekly updates and share to unit head
Prepare monthly unit performance report to share with Unit head
Maintain accountable goal display board to keep functions in track for achieving their goals

Conduct Trainings or Boot camp to create awareness about manufacturing transformation.

Provide Jaagruti induction training to new joined employees
Conduct boot camps on Jaagruti tools i.e. Performance dialogue, OEE, SMED and Waste identification & Elimination
Conduct Awareness session on efficiency and changeover improvement

Key Accountabilities (6/6)Major ChallengesSustaining the Jaagruti KPIs which are:Planning KPIs.: OTIF, D2D time and ThroughputProduction KPIs. : Process cycle time, Changeover time, Yield, OEE, Efficiency and Run rate of production.Challenge overcome by daily, weekly and monthly monitoring, set benchmark for each KPI, create awareness and continue improvementsKey Interactions (1/2)

Production for day to day activities like PD (Daily)
QA for periodic activity idea generation and evaluations (need basis)
Warehouse for PD, time motion study, material movement day to day activity (daily)
Engineering for tracking daily breakdown day to day activity (daily)
HSE for routine safety (need basis)
HR for HR related ideas, awards need basis

Admin for need basisKey Interactions (2/2)Dimensions (1/2)

Brain-storming session conducted annually: 12
Average 100 ideas generated in a year
PD score should be maintain above 75%
OTIF should be more than 95%
D2D time should be below the baseline of each dosage form
100% adherence to manufacturing KPIs
Continue improvement in OEE and to maintain efficiency above 70%
Sustaining the yield of products above 97.00%

Changeover time of machine maintain with standard defined timeDimensions (2/2)Key Decisions (1/2)Action items for continuous improvements (Department head, Unit Head)Idea evaluation (Department head, Unit Head)Recommendation generated from Yield improvement study (Department head, Unit Head)Key Decisions (2/2)Education QualificationGraduate in Chemical EngineeringRelevant Work Experience3-5 years of industrial engineer

Knowledge of Lean manufacturing
Knowledge of Kaizen principle and Its implementation

Knowledge about computer (Excel, ppt and Word file).

Cipla

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