Perfetti Van Melle - Senior Manager - Operational Excellence

Location: Rudrapur Work mode - 6 days Role Purpose The Senior Manager Operational Excellence will lead strategic and continuous improvement initiatives across manufacturing, supply chain, and operations, with a strong focus on productivity, quality, cost optimization, capacity utilization, and operational excellence. The role will be responsible for: - Driving Lean, Six Sigma and TPM initiatives to improve OEE and reduce operational losses. - Leading cross-functional improvement projects aligned with business OGSM (Objectives, Goals, Strategies and Measures). - Developing and implementing the Continuous Improvement strategy, governance, and operating rhythm. - Building problem-solving capabilities across teams and coaching operational leaders. - Monitoring key operational KPIs and providing actionable insights to senior leadership. - Leading Value Engineering, Capacity Optimization, Line Balancing, and Digital Transformation initiatives. - Strengthening the overall culture of continuous improvement and data-driven decision-making across the plant. Key Responsibilities 1. Daily Management System - Lead and strengthen the Daily Management System - POS across the plant. - Drive adherence to POS standards and routines across functions. - Identify and close gaps emerging from POS audits, ensuring achievement of target scores. - Support plant leadership in establishing a strong performance management and review cadence. - Use daily management data to identify performance gaps and prioritize improvement opportunities. 2. Problem Solving and Continuous Improvement - Lead Root Cause Analysis (RCA) initiatives and support production teams in improving OEE and eliminating chronic losses. - Drive structured problem-solving using Lean Six Sigma, statistical tools, and data-driven methodologies. - Train and coach operators and teams. - Develop an appreciation of the S&OP process and its linkage with operating hours, capacity utilization, and production planning. - Lead and deliver cross-functional statistical improvement projects. - Coach project managers and operational teams in structured problem-solving and project execution. - Lead programs and manage portfolios of improvement initiatives across functions. - Conduct Value Stream Mapping (VSM) and Line Balancing to identify and address chronic operational issues. - Identify opportunities to improve productivity, reduce waste, optimize costs, and enhance quality. 3. Capability Development - Mentor teams and build organizational capability in Continuous Improvement, Lean Six Sigma, and structured problem-solving. - Develop and execute capability-building programs through the LSS Calendar cycle. - Conduct skill assessments of operators and identify capability gaps. - Lead targeted improvement and training programs to close identified capability gaps. - Build a strong pipeline of internal CI champions and problem-solving practitioners. 4. Capacity Planning and Budgeting - Develop a strong understanding of Capacity Planning and OEE Loss Trees and their linkage to short-term and long-term factory budgeting. - Support capacity optimization initiatives based on demand, operating hours, OEE, and available resources. - Develop an understanding of and contribute to budgeting processes related to: Energy, Labour, Maintenance, Repairs, and Operational efficiency. - Identify opportunities to improve cost efficiency through productivity and operational improvement initiatives. - Work collaboratively with multiple departments and functions to align operational improvement priorities with business requirements. 5. Digitization and Industry 4.0 - Lead Industry 4.0 and manufacturing digitization initiatives across the plant. - Develop a strong understanding of the automation pyramid and its application within manufacturing environments. - Identify opportunities to digitize manual processes, reports, and performance-monitoring systems. - Lead small- to medium-scale digitization projects related to manufacturing reporting and operational performance. - Leverage data and digital tools to improve visibility, decision-making, and operational efficiency. Qualifications and Certifications Educational Qualifications - Bachelor's degree in Engineering or a related technical discipline. - Master's degree preferred. Certifications - TPM Expert / Black Belt Certification from a recognized institution/body such as ASQ, JIPM, or equivalent. - Lean Six Sigma certification preferred. Experience - 8 - 12 years of overall professional experience. - Minimum 4 - 5 years of experience in FMCG / manufacturing environments, preferably in an Operational Excellence / Continuous Improvement role. - Proven experience in leading Continuous Improvement programs and cross-functional teams. - Demonstrated experience in driving measurable improvements in OEE, productivity, cost, quality, capacity utilization, and operational performance. - Experience in leading multiple improvement projects/programs simultaneously.