SC&O; - Manufacturing Excellence

Manager / Senior Manager

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Summary: A career in our Operations and Manufacturing Excellence practice will provide you with the opportunity to help our clients unlock latent capacity, improve throughput and reduce the total cost of manufacturing across their plant network. We focus on manufacturing operations strategy, shop-floor productivity and debottlenecking, quality and cost of poor quality reduction, material and energy efficiency, production planning and scheduling, and digital manufacturing to drive both margin expansion and service performance.

You will be a part of a team that helps organisations transform their manufacturing operations into a source of competitive advantage. You will work at the client site with plant leadership and shop-floor teams to diagnose constraints, design and deploy Lean, Six Sigma and TPM, build capability at all levels, and embed a management operating system that sustains the gains after we exit.

Responsibilities -

- Lead end-to-end manufacturing excellence engagements - from diagnostic and opportunity baselining through pilot, scale-up and sustenance - with explicit, quantified impact on throughput, cost and quality.
- Conduct plant diagnostics on dimensions of OEE, line balancing analysis, value stream mapping, constraint (bottleneck) identification, material wastages and process capability studies to size the improvement opportunity.
- Conduct manpower productivity assessment, suggest improvement areas and drive implementation.
- Drive throughput improvement and debottlenecking through Theory of Constraints, SMED/quick changeover, cycle time reduction, line rebalancing, layout and material flow redesign, and elimination of the seven wastes.
- Deploy Lean and shop-floor improvement methodologies - 5S, Kaizen and Gemba walks, Standard Work, Poka-Yoke, Jidoka, Heijunka, Kanban and pull systems, TPM (autonomous and planned maintenance) and Hoshin Kanri.
- Lead structured Six Sigma problem solving (DMAIC) on chronic losses, supported by statistical analysis on available softwares.
- Design and run quality improvement programmes to reduce Cost of Poor Quality (COPQ) and improve Right First Time (RFT), first pass yield, rework, rejection and warranty/field failure performance using 7QC tools, FMEA, 8D, Why-Why and root cause analysis.
- Reduce material consumption variability - establish standard consumption norms, analyse yield and give-away, control process losses, scrap and shrinkage, and institutionalise material balance and variance governance.
- Deliver energy cost reduction through energy mapping and balances,



specific energy consumption (SEC) benchmarking, utility and compressed air/steam system optimisation, load and tariff optimisation, and no/low-cost operating practice changes.
- Link production scheduling to throughput - improve finite capacity scheduling, sequencing and changeover-aware campaign planning, bottleneck-driven schedule design, adherence to plan, batch sizing and WIP control, and S&OP; to shop-floor execution linkage.
- Build and deploy the Management Operating System - daily work management, tiered review structures, KPI dashboards, visual management and performance dialogues - to sustain and lock in benefits.
- Quantify, track and defend benefits with the client Finance function, and build the business case for capital-light versus capital-intensive interventions.
- Manage the day-to-day client relationship at plant and corporate level, lead workstreams and coach client teams to run improvement cycles independently.
- Contribute to business development through proposals, point of view, sector diagnostics and capability building assets for the practice.
- Arrange appropriate assignments and experiences to support others’ learning and development.
- Uphold the PwC code of ethics and business conduct.
- Understanding of leveraging MES / Scada data to create digital analytics-based dashboards for faster decision making

Mandatory Skills

- Link production scheduling to throughput - improve finite capacity scheduling, sequencing and changeover-aware campaign planning, bottleneck-driven schedule design, adherence to plan, batch sizing and WIP control, and S&OP; to shop-floor execution linkage.
- Build and deploy the Management Operating System - daily work management, tiered review structures, KPI dashboards, visual management and performance dialogues - to sustain and lock in benefits.
- Quantify, track and defend benefits with the client Finance function, and build the business case for capital-light versus capital-intensive interventions.
- Manage the day-to-day client relationship at plant and corporate level, lead workstreams and coach client teams to run improvement cycles independently.
- Contribute to business development through proposals, point of view,



sector diagnostics and capability building assets for the practice.
- Arrange appropriate assignments and experiences to support others’ learning and development.
- Uphold the PwC code of ethics and business conduct.
- Understanding of leveraging MES / Scada data to create digital analytics-based dashboards for faster decision makingManufacturing excellence, operations improvement or plant performance transformation experience in a consulting firm or in a manufacturing operations/CI role.
- Demonstrated delivery of throughput improvement and debottlenecking outcomes - OEE improvement, cycle time and changeover reduction, line balancing, capacity release without major capex.
- Strong Lean toolkit - Value Stream Mapping, 5S, Standard Work, SMED, Kanban/pull, Heijunka, Poka-Yoke, waste elimination.
- Six Sigma problem solving with hands-on DMAIC delivery; Green Belt mandatory, Black Belt preferred, with working knowledge of SPC, MSA, DOE and process capability.
- Japanese manufacturing methodologies - TPS, TPM, Kaizen/Gemba, Jidoka, Hoshin Kanri, Monozukuri thinking and Daily Work Management.
- Quality improvement delivery with measurable COPQ reduction and RFT/first pass yield improvement, using FMEA, 8D, Why-Why and 7QC tools.
- Material consumption variability reduction - norm setting, yield and loss analysis, scrap/rework control and material variance governance.
- Energy cost reduction - energy balance, specific energy consumption benchmarking, utilities optimisation and operating practice improvement.
- Production planning and scheduling expertise, including finite capacity scheduling, sequencing, changeover optimisation, schedule adherence and the link between scheduling discipline and throughput.
- Strong data analysis skills (Excel, Minitab, SPSS; Power BI or equivalent) and the ability to convert shop-floor data into a quantified opportunity baseline.
- Ability to work at the Gemba with operators, supervisors and plant leadership, and to influence senior stakeholders with structured, fact-based recommendations.
- B.E./B.Tech in Mechanical, Production, Industrial, Chemical, Electrical or Metallurgical Engineering; MBA is must.

Preferred skill sets

- Experience working in the Consulting Industry on large-scale operations transformation programmes.
- Sector depth in Automotive and auto components, Industrial products, Metals, Cement, Chemicals, Consumer goods or Process industries.
- Certified Six Sigma will be added advantage.
- Exposure to SAP PP, QM or PM modules - functional or business user.

📌 Manager (Gurugram)
🏢 PwC
📍 Gurugram