- Identify and Drive Continuous Improvement projects through structured analysis to improve plant performance metrics
- Develop, engage and enable people for analytical thinking, improve individual skillsets across functions, build the capability to improve the application of problem solving tools in order to be able to adopt the benchmarked manufacturing excellence practices
B. Primary responsibilities
Strategic and planning
- Support the CI manager in execution of CI strategy
- Identify yearly Improvement areas and accordingly plan projects for the plant
- Create an assessment structure to measure the effectiveness of CI initiatives vis-a-vis the envisaged project outcome
Functional
Core
- Facilitate and develop detailed project plans along with project leaders for all identified CI projects in the plant including DMAIC activity plan for each project
- Analyse project data and conduct observation studies in every project
- Coordinate action plans for project delivery (for every CI project at the plant)
- Monitor and communicate project status periodically to all stakeholders
- Support in execution of 6 sigma (Black Belt/Green Belt/Yellow Belt) Training Calendar.
- Facilitate implementation of Kaizen Mechanisms to drive small improvements across the plant
- Facilitate Small Group Activity teams / Quality Circle Teams for Problem Solving.
- Conduct Value Stream Mapping/ Bottleneck and Cycle Time studies for Process Improvements
- Monitor daily project wise actionable/observation studies/trials and the project participation of the stakeholders through various systemic methods
- Support Manufacturing/Production Project Leaders to conduct trials as per protocols
- Creation of training module for various CI skill sets (TPM, Six Sigma, etc.)
Internal process
- Facilitate weekly Project Reviews with Plant Project team,
Plant Head and Functional CIC Head
- Facilitate monthly Plant Steering committee reviews
- Escalate delays and non-compliances to CI Manager and plant head.
- Creation of Projects Dashboard for Plant Heads Review
- Conduct GEMBA walks with Mfg. Head to regularly identify potential areas of improvements and track the implementation of the same.
- Conduct Kaizen Idea Workshops across the plant
People development
- Train the identified people by respective process owners for Kaizen. Identify & develop project teams for analytics and sustenance of improvements
- Support in design and execution of Quarterly Kaizen Events, yearly Six Sigma Project competitions for employees.
C. Key Result Areas
- No of processes standardized through various CI projects
- No. of Kaizen Projects Completed vs planned
- No. of People Trained & Certified in Six Sigma Methodology against planned
- Compliance to Kaizen Idea Workshops & Events as per Plan
- GEMBA Walks Improvements Planned vs Actuals
D. Key Interfaces
Internal Interfaces
External Interfaces
- Production
- Quality
- Maintenance
- Post Manufacturing
- HR
- Central CIC