Role Title

Engineering Excellence Manager/ Sr.Manager - Bottle Packaging

Function

Engineering Excellence

Reporting to

EE Lead

Team Size

Individual Contributor

Work Location

Ahmedabad

Role Purpose The Engineering Excellence Executive will support the deployment and sustenance of Engineering Excellence and TPM initiatives within the Bottle Packaging area. The role focuses on enhancing equipment reliability, improving Overall Equipment Effectiveness (OEE), reducing losses, and driving continuous improvement through TPM, Lean, and operational excellence tools.

The binding will serve as the subject matter expert for Bottle Packaging machines, working closely with Production, Engineering, Quality, and Maintenance teams to improve machine performance, reduce downtime, trouble shoot, and build operator capability.

Key Responsibilities

Bottle Packaging Equipment Excellence

- Act as the Engineering Excellence central point for Bottle Packaging Machines.
- Analyse machine performance, downtime, speed losses, and quality defects to identify improvement opportunities.
- Support initiatives to improve OEE, productivity, machine reliability, and operational efficiency.
- Collaborate with production and maintenance teams to eliminate equipment losses.

Continuous Improvement

- Facilitate Kaizen projects, FMEA, Why-Why Analysis, and Root Cause Analysis projects related to Bottle Packaging operations.
- Drive improvement initiatives focused on:
- Failure phenomenon elimination
- Alarm reduction
- Breakdown Reduction
- Defect Elimination
- 5S Excellence
- Waste Reduction
- GMP Improvement Projects
- Track perks realization and sustainability of implemented improvements.

Process Optimization and Shop-Floor Engagement

- Drive process optimization and operational excellence initiatives in Bottle Packaging operations through process mapping, value stream mapping, and regular Gemba walks to identify bottlenecks, eliminate waste, and improve overall productivity.
- Analyse machine and process performance to identify opportunities for enhancing resource utilization, line efficiency, and equipment effectiveness.
- Develop, implement,



and sustain operational standards and best practices to optimize machine performance and ensure consistent production output.
- Collaborate closely with operators, supervisors, and maintenance teams to resolve operational challenges, reduce losses, and improve process reliability.
- Foster a culture of problem-solving, employee engagement, and continuous improvement by promoting shop-floor ownership and participation in improvement initiatives.

Training & Knowledge Building

- Prepare and deliver One-Point Lessons (OPLs), SOP training, and FMEA / FTA
- Support skill development of operators and technicians on Bottle Packaging equipment.
- Facilitate knowledge sharing and best-practice implementation across packaging lines.

Data Analysis & Reporting

- Monitor and analyse production, OEE, downtime, quality, and changeover data.
- Develop dashboards and reports using MS Excel and PowerPoint.
- Present improvement project outcomes, performance trends, and recommendations to management.

Stakeholder & Employee Engagement

Internal:

- Production Teams Operators, Supervisors, Shift In-Charges and Packaging Managers.
- Engineering Teams Reliability improvement, breakdown reduction, and AM implementation.
- Quality Assurance & Quality Control GMP compliance, quality improvement, and defect reduction initiatives.
- Supply Chain & Planning Throughput improvement and production flow optimization.
- HR & Learning & Development – Training coordination and employee engagement initiatives.

External:

- Machine Manufacturers/OEMs – Technical support and machine performance improvement.
- Vendors & Technology Partners – Equipment upgrades, automation, and digital manufacturing solutions.
- Industry Bodies (CII, TPM Clubs, Lean Forums) – Participation in benchmarking and TPM excellence programs.

Soft Skills & Tools Demonstrate strong proficiency in MS Excel and PowerPoint for reporting,



analysis, and presentations.

Dimensions-

Ahmedabad based location

Behavioural Competencies

Collaboration

Expert

Problem-Solving Mindset

Expert

Adaptability

Expert

Communication Skills

Expert

Continuous Learning

Expert

Functional Skills

Bottle Packaging Machine Expertise: Strong understanding of Bottle Packaging equipment, machine settings, troubleshooting, change parts management, and performance optimization.

Expert

ME & TPM: Knowledge of TPM pillars, Autonomous Maintenance, Focused Improvement, OEE management, and loss elimination techniques.

Intermediate

Continuous Improvement: knowledge in Kaizen, FMEA, Why-Why Analysis, RCA, 5S, Visual Management, and waste elimination methodologies.

Intermediate

Process Optimization: Experience in Process Mapping, Value Stream Mapping, SMED, and productivity enhancement projects.

Intermediate

Training & Knowledge Transfer: Ability to conduct shop-floor training sessions, workshops, and OPL development.

Expert

Analytical & Data Management: Ability to analyse operational data and convert insights into improvement actions.

Expert

Soft Skills & Tools: Proficient in MS Excel, PowerPoint, and performance dashboard preparation.

Expert

Job Specifications

Exposure

- Hands-on experience with Bottle Packaging Machines in pharmaceutical manufacturing.
- Exposure to TPM deployment, OEE improvement, Autonomous Maintenance, and Lean Manufacturing initiatives.
- Experience in SMED, throughput improvement, and loss reduction projects.
- Shop-floor engagement experience through Gemba, Kaizen, and operator capability-building programs.

Experience Level
- 10+ years of experience in production (Pharma) / OEM
- Proven experience in Bottle Packaging equipment operation, troubleshooting, or performance improvement.

Education
- Bachelor’s degree/ B Pharm
- Master’s degree in operations/industrial management preferred but not mandatory.

Certifications
- Lean Manufacturing / TPM Certification preferred.
- Green Belt certification will be an added advantage.
- Training in TPM, Kaizen, SMED, or Operational Excellence methodologies preferred.

📌 Engineering Excellence Manager/ Sr.Manager - Bottle Packaging (Ahmedabad)
🏢 Zydus Lifesciences
📍 Ahmedabad