Website:
greenmile.co.in
Job details:
Job DescriptionConsultant – Lean & Operational Excellence (Industrial Engineering)Reports To
Lead Consultant – Lean & Operational Excellence
Location
Hosur
Role Overview
The Consultant – Lean & Operational Excellence (Industrial Engineering) will lead and support transformation initiatives focused on improving productivity, quality, cost, delivery, safety, and operational performance across manufacturing and service organizations. The role combines Lean Consulting, Operational Excellence, and Industrial Engineering practices to drive sustainable business improvements through process optimization, workforce productivity enhancement, capacity improvement, and waste elimination.
The consultant will work closely with client leadership teams, plant management, production teams, maintenance teams, and cross-functional stakeholders to identify improvement opportunities, design future-state operations, and execute transformation roadmaps that deliver measurable business results.
Key ResponsibilitiesLean Consulting & Operational Excellence
· Lead and support Lean transformation programs across manufacturing and operational environments.
· Conduct Operational Excellence assessments, maturity evaluations, and diagnostic studies.
· Facilitate Lean workshops, Kaizen events, problem-solving sessions, and continuous improvement initiatives.
· Drive implementation of Lean Manufacturing principles and waste elimination strategies.
· Conduct Value Stream Mapping (VSM) and future-state design initiatives.
· Implement Lean tools including:
o 5S & Workplace Organization
o Visual Management
o Kanban Systems
o SMED (Quick Changeover)
o Standard Work
o Poka-Yoke
o Line Balancing
o JIT & Pull Systems
o Daily Management Systems
· Support deployment of Lean Culture and Continuous Improvement frameworks.
· Develop and monitor Lean performance metrics and improvement roadmaps.
Industrial Engineering & Productivity Improvement
· Conduct work measurement, time studies, motion studies, and productivity analysis.
· Perform manpower optimization and workforce productivity assessments.
· Lead line balancing, takt time analysis, capacity planning, and production flow optimization.
· Analyze plant layouts and material flow to improve operational efficiency.
· Conduct facility planning and space utilization studies.
· Support labor productivity improvement initiatives.
· Develop standard times, productivity benchmarks, and performance standards.
· Drive throughput improvement and bottleneck elimination projects.
· Support inventory optimization and supply chain efficiency initiatives.
· Recommend engineering and process improvements to enhance operational performance.
TPM, Quality & Process Improvement
· Support Total Productive Maintenance (TPM) implementation and sustainability.
· Monitor and improve Overall Equipment Effectiveness (OEE).
· Facilitate Autonomous Maintenance and Focused Improvement activities.
· Support Preventive and Predictive Maintenance initiatives.
· Drive process quality improvement initiatives using TQM principles.
· Conduct Root Cause Analysis using:
o 5 Why Analysis
o Fishbone Diagram
o Pareto Analysis
o FMEA
o Fault Tree Analysis
· Support defect reduction, process stabilization, and variation reduction initiatives.
Client Consulting & Project Execution
· Engage with client stakeholders to understand operational challenges and business objectives.
· Conduct operational assessments, Gemba walks, and process audits.
· Facilitate stakeholder workshops and review meetings.
· Develop implementation plans and transformation roadmaps.
· Track project execution against defined milestones and deliverables.
· Monitor action closures and implementation effectiveness.
· Prepare client presentations, reports, dashboards, and executive summaries.
· Identify project risks and escalate issues appropriately.
Performance Analytics & Business Improvement
· Analyze operational and business performance data.
· Monitor KPIs related to:
o Productivity
o OEE
o Throughput
o Quality
o Cost
o Inventory
o Delivery Performance
o Capacity Utilization
· Develop performance dashboards and management reporting systems.
· Quantify financial benefits and business impact from improvement initiatives.
· Support data-driven decision-making and performance management processes.
· Utilize analytical tools for operational improvement studies.
Process Governance & Standardization
· Develop SOPs, work instructions, and standard operating frameworks.
· Support ISO, TPM, TQM, and operational audit requirements.
· Conduct process audits and compliance reviews.
· Establish governance mechanisms for improvement initiatives.
· Maintain project documentation, action trackers, and best-practice repositories.
· Support organizational capability-building and knowledge management initiatives.
Digital Manufacturing & Industry 4.0
· Support Industry 4.0 and Smart Manufacturing initiatives.
· Identify opportunities for process automation and digitization.
· Assist in implementation of MES, digital dashboards, and production monitoring systems.
· Support operational data collection, visualization, and analytics projects.
· Collaborate with technology teams to improve operational visibility and decision-making.
Key Skills & CompetenciesLean & Operational Excellence
· Lean Manufacturing
· Lean Transformation
· Operational Excellence
· Continuous Improvement
· Kaizen
· TPM
· TQM
· Daily Management Systems
· Value Stream Mapping (VSM)
Industrial Engineering
· Time & Motion Study
· Work Measurement
· Productivity Improvement
· Line Balancing
· Capacity Planning
· Plant Layout Optimization
· Material Flow Analysis
· Workforce Optimization
· Facility Planning
· Production Systems Engineering
Analytical & Problem-Solving Tools
· Root Cause Analysis
· 5 Why
· Fishbone Diagram
· Pareto Analysis
· FMEA
· SPC
· Minitab
· Advanced Excel
· Power BI (Preferred)
Consulting & Leadership Skills
· Stakeholder Management
· Facilitation & Workshop Leadership
· Project Management
· Change Management
· Presentation & Communication Skills
· Structured Problem Solving
· Data-Driven Decision Making
Qualification & Experience
· B.E / B.Tech in Industrial Engineering, Mechanical Engineering, Production Engineering, Manufacturing Engineering, or related disciplines.
· Diploma holders with relevant Industrial Engineering and Lean experience may be considered.
· 3–8 years of experience in:
o Lean Manufacturing
o Operational Excellence
o Industrial Engineering
o Productivity Improvement
o Manufacturing Consulting
o Continuous Improvement
o TPM / TQM Initiatives
o Process Excellence
· Lean Six Sigma Green Belt preferred.
· Lean Six Sigma Black Belt certification is an added advantage.
Key Performance Indicators (KPIs)
· Productivity Improvement (%)
· OEE Improvement (%)
· Throughput Enhancement
· Cost Reduction Achieved
· Waste Reduction
· Inventory Reduction
· Lead Time Reduction
· Number of Kaizen Initiatives Implemented
· Capacity Utilization Improvement
· Project Milestone Adherence
· Savings Realization from Improvement Projects
· SOP Implementation Effectiveness
· Client Satisfaction Scores
· Sustainability of Implemented Improvements
Behavioral Expectations
· Strong consulting and client-facing mindset
· Ownership and accountability for results
· Continuous improvement orientation
· Analytical and structured thinking capability
· Strong execution and follow-through
· Ability to influence and drive change
· High learning agility and adaptability
· Collaborative and team-oriented approach
· Professional communication and stakeholder engagement skills
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