- Conduct detailed time studies using methodologies such as MOST for both current and existing processes.
- Develop and maintain cell wise and product wise line capacity sheets and ensure timely updates.
- Drive productivity improvement through low-cost automation, alternate process recommendation, conveyorization for material movement, layout enhancements, and manpower optimization.
- Study and optimize workstation ergonomics to improve operator safety and efficiency.
- Execute debottlenecking projects
- 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
- Reduce indirect consumable material wastage by finding alternate low-cost material like cutting inserts, cutting oil, or with increased life
Continuous Improvement Initiatives
- Drive Kaizen and other lean initiatives to achieve cost and efficiency targets.
- Analyse production data to identify opportunities for process improvements.
- Perform process capability & Process qualification studies as and when required
- Collaborate with cross-functional teams to address quality and productivity issues through root cause analysis and implementation of corrective measures
Tooling and Documentation Management
- Develop and maintain process documentation, including process flow charts, PFMEA, control plans, IPO, and work instructions.
- Modify and improve existing tools, jigs, and fixtures to enhance efficiency and reduce setup times using SMED and poka-yoke techniques
Manufacturing Excellence System
- Drive PQCDSM agenda for the plant- set targets, evaluate, monitor, and report to Plant Head.
Collaboration and Training
- Work closely with Operations, QA and Maintenance teams to ensure process reliability and quality standards are met.
- Train operators and technicians on process improvements and new operational standards.
- Creating awareness on 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