Process Improvement Engineer

Responsibilities

The ideal candidate will but is not limited to:

• Identify bottlenecks and eliminate non-value-added activities across blending, filling, plastics, and warehouse operations.
• Improve process efficiency & throughput across all operational units.
• Reduce machine downtimes and optimize machine utilization and manpower distribution across all unit operations.
• Reduce cycle times without compromising quality.
• Ensure processes are repeatable and controlled.
• Track and analyse key operational metrics such as OEE and process reliability to derive valuable insights.
• Develop interactive performance tracking reports for daily, weekly, monthly, quarterly, and yearly operations.
• Apply data and analytics to identify important trends, losses, and improvement opportunities.
• Lead detailed and well-structured problem-solving roadmaps using standard qualitative and quantitative methodologies and tools cross-functionally.
• Identify root causes and not superficial causes or symptoms across all units.
• Identify & execute corrective and preventive actions CAPA sustainably.
• Ideate and lead cost-saving continuous improvement projects using lean six-sigma methodologies like DMAIC, DMADV, PDCA, etc., yielding measurable deliverables.
• Sustain, document, and standardize improvements made.
• Work closely with warehouse, logistics, sales, maintenance, and quality teams to ensure smooth material and process flows across all departments.
• Train operators and other personnel on problem-solving techniques
• Build a culture of continuous improvement across the entire plant.
• Conduct daily shop floor walkthroughs.
• Engage operators to identify issues and implement solutions in real time.

Requirements

• Education Bachelor’s degree in engineering or related field [with a minimum of second class – upper division
• Master’s degree will be an added advantage
• Experience: 1-3 years in manufacturing or related industries
• Strong ownership mindset.
• Challenge the status quo mentality.
• Excellent communication skills.
• Strong knowledge of lean manufacturing processes.
• Strong analytical, visualization, and problem-solving skills.
• Comfortable working with other departments’ personnel.
• Ability to learn a novel process in short time.
• Physically, mentally, and psychologically fit.

Required Competencies:

• Overall Equipment Effectiveness: Enhancement of OEE in production units. Improve an operational unit’s OEE by 5% in a quarter across all units.
• Downtime: Reduction of downtimes in production units. Decrease a production unit’s downtime by 5% in 3 months across multiple production units.
• Wastes: Wastage reduction in production units. Cut down wastes by 5% in a quarter across multiple production units.
• Continuous Improvement Projects: Lean Projects. Complete at least 3 lean projects in the plant in a year.
• Continuous Improvement Projects: Six Sigma Projects. Complete at least 2 six sigma projects in the plant in a year.