- Prepare and maintain updated cell-wise and product-wise line capacity sheets, and review them with the Plant Head / Cluster ME Head for adequacy of current products
- Keep latest shop floor layout ready with due approvals
- Provide production manpower estimation as per indent plan after analyzing opportunities and
flow for improvement of workstation ergonomics and implement necessary actions
- Study production process at granular level and do time study using MOST methodology for new
products as well as current products as and when requested
- Execute debottlenecking projects as given by Cluster ME Head.
- Achieve Quality Improvements by doing defect analysis with QA and take actions on root cause
by providing Preventive & Detective countermeasures. Fill PCRN, get it approved and implement
- Do process capability & Process qualification studies as and when required
- Productivity Improvement and Reduce direct manpower by low cost automation solutions,
alternate process recommendation, conveyorization for material movement, layout
improvement etc.
- Reduce indirect consumable material wastage by finding alternate low-cost material like
cutting inserts, cutting oil, or with increased life
- Find and propose alternate process with lower process cost
- Drive productivity and flow Improvements through industrial engineering effort of line balancing,
material flow, man motion, station design study .
- Analyze opportunities and flow for improvement of workstation ergonomics and implement
necessary actions
- Preparing and update the standard formats & master plan
- Preparing Annual Audit Plan
- Scheduling monthly cross Audit
- Monitoring the monthly audit plan implementation status
- Compilation of Section wise audit reports
- Scheduling 5s audit review meeting with plant head, capturing MOM and preparing action plan
- Monitoring the action plan status against the action plan
- Plant section wise 5s measurable result capturing & verifying
- Maintaining plant operations as per the 5s standards and facing external 5s audit.
- Preparing action plan as per NC’s & monitoring the status till NC closer.
- Setting TPM pillar wise targets & preparing master plan of each pillar
- Providing resources for pillar implementation pre-preparation.
- Plan and providing pillar wise training to circle members
- Plan and conduct weekly pillar review with the respective pillar lead.
- Planning MES review meeting with plant head, capturing MOM and preparing action plan
- Monitoring the action plan status against the action plan
- Identifying cost efficiency & cost saving CI opportunities and monitoring the progress
- Support plant for identifying and distributing monthly Kaizen awards.
- Preparing PQCDSM report for monitoring plant performance on various aspects
- Planning PQCDSM meeting with plant head, capturing MOM and preparing action plan
- Conducting physical verification of improvement and saving projects
- Creating awareness for 5S, OpEx Pillars, VSM, Line balancing / work study and its benefit to the
individual and organization as well.
- Conduct various internal competitions like, Kaizen, posters & slogans etc.
- Nurture Kaizen culture in the Plant by taking various initiatives
