Role & responsibilities

A. Software & Systems Implementation (Warehouse and Manufacturing Units)

- Support end-to-end rollout of operational software ERP (TallyPrime), Warehouse Management System (WMS), Sales Force Automation (Bizom), barcode / handheld scanning and internal mobile apps across plants, warehouses and depots.
- Gather and document requirements from user departments (production, stores, dispatch, QA, accounts) and translate them into clear functional specifications for the IT team and external vendors.
- Prepare and clean master data (SKU, BOM, location, bin, warehouse, party and rate masters) required for system go-live.
- Design and execute User Acceptance Testing (UAT) — write test cases, run test cycles, log defects, follow up with vendors until closure, and sign off before go-live.
- Plan and run cutover activities: opening stock upload, bin mapping, parallel run, and go-live day support at site.
- Train shop-floor, store and dispatch users on the new system; prepare user manuals, quick-reference cards and short how-to videos in local language where needed.
- Provide hypercare and post-go-live support — track adoption, resolve user issues, and escalate recurring gaps as change requests.
- Audit system usage against defined process: check that transactions are being posted correctly and on time, and correct process drift at source.

B. SOP Creation & Process Documentation

- Map existing processes (AS-IS) through shop-floor observation, gemba walks and user interviews; design improved TO-BE processes.
- Write clear, illustrated SOPs, work instructions and process flowcharts for manufacturing, packing, stores, warehouse and dispatch operations.
- Design operating formats, checklists, tags and registers — both physical and digital — that support the SOP.
- Maintain a controlled SOP library with version control, review dates, approval trail and a document master list.
- Conduct SOP training and periodic refreshers; verify adherence through floor audits and close gaps with corrective action.
- Keep SOPs aligned with FSSAI, ISO / FSSC 22000, HACCP and internal quality requirements, in coordination with the QA team.

C. Process Excellence & Continuous Improvement

- Conduct time & motion studies, work sampling and method studies to establish standard times, manpower norms and output targets.




- Carry out line balancing, workstation design and material flow / layout improvement for production and packing lines.
- Identify and eliminate the seven wastes (TIMWOOD) through Lean tools — 5S, Kaizen, Poka-Yoke, Visual Management, Standard Work and Value Stream Mapping.
- Run structured Kaizen events and drive employee suggestion schemes; quantify and track savings from each initiative.
- Prepare capacity models and manpower plans; support make-vs-buy, shift-pattern and productivity decisions with data.
- Build the business case (cost–benefit, payback) for process and automation investments.

D. Six Sigma & Structured Problem Solving

- Execute DMAIC projects on defined problem statements — line rejections, packing weight variation, dispatch errors, inventory mismatch, order fill rate, downtime.
- Design data collection plans; use statistical tools — Pareto, control charts, capability studies (Cp / Cpk), hypothesis testing, regression, MSA — to locate root cause.
- Apply structured RCA methods (5 Why, Fishbone, FMEA, Why-Why analysis) and validate solutions before scale-up.
- Establish control plans and monitoring dashboards so gains sustain after project closure.
- Present project progress and results to management through regular reviews and tollgate presentations.

E. Warehouse & Supply Chain Engineering

- Design warehouse layout, storage systems, bin / slotting logic and material flow to improve space utilisation and picking productivity.
- Standardise inward, put-away, picking, packing, loading and dispatch processes; define and track TAT for each.
- Implement FIFO / FEFO discipline, batch and expiry control, and cycle counting to improve inventory accuracy.
- Reduce damages, expiry, shortages and returns through better handling standards and root cause tracking.
- Standardise processes across own warehouses, depots and distributor points so that every location runs the same way.

F.



Manufacturing Operations Support

- Track and improve OEE — availability, performance and quality — for key lines; drive down breakdown and changeover losses.
- Reduce changeover time using SMED principles.
- Monitor yield, process loss, rework and packing material wastage against norms; investigate deviations.
- Support new product / current pack introduction: standard time setting, line trials, BOM validation and process readiness.
- Coordinate with maintenance and QA on process-related quality and reliability issues.

G. MIS, Data & Reporting

- Build and maintain operational dashboards and daily / weekly / monthly MIS on productivity, yield, wastage, TAT, inventory accuracy and project savings.
- Define operational KPIs with owners and targets, and publish performance against them.
- Use Excel (advanced), Power BI and system reports to convert raw operational data into decisions.
- Maintain a project tracker covering all improvement and implementation initiatives with status, owner and impact.

H. Audits, Compliance & Training

- Conduct periodic process and 5S audits at plants, warehouses and depots; publish scores and drive closure of findings.
- Support internal, customer and statutory audits with process documentation and evidence.
- Build capability of frontline teams through structured training on SOPs, Lean basics and system usage.

I. Project & Stakeholder Coordination

- Run assigned projects with a defined plan, milestones, risks and review cadence.
- Coordinate across production, stores, dispatch, QA, sales, finance and IT, and with external software vendors and consultants.
- Travel to plants, warehouses and distributor locations as required for studies, rollouts and audits.

Preferred candidate profile To drive process standardisation, productivity improvement and technology adoption across our manufacturing units, warehouses and distribution network. The role sits at the intersection of industrial engineering and business systems — studying how work is actually done on the shop floor and in the warehouse, redesigning it to remove waste, documenting it as SOPs, and then implementing the software (ERP / WMS / SFA / mobile apps) that locks the improved process in place and makes it measurable.

📌 Process Excellence Analyst, Industrial Engineer (Bengaluru)
🏢 Swastiks Masalas Pickles u0026 Food Products
📍 Bengaluru