Junior Engineer - Lean Manufacturing

Job Description: Junior Engineer - Lean Manufacturing

Department - Operations / Manufacturing Excellence

Location - Silvassa

Position Summary

The Junior Engineer - Lean Manufacturing is responsible for driving operational excellence across the organization through the implementation and sustainment of Lean Manufacturing principles, continuous improvement initiatives, waste elimination programs, productivity enhancement, quality improvement, and cost optimization. The role focuses on building a culture of continuous improvement while ensuring alignment with business objectives related to safety, quality, delivery, cost, and employee development.

Key Responsibilities

1. Lean Strategy & Deployment

• Develop and execute the organization's Lean Manufacturing roadmap.
• Lead the implementation of Lean tools and methodologies across all manufacturing functions.
• Align Lean initiatives with business goals and operational KPIs.
• Establish and monitor Lean maturity levels across plants and departments.

2. Continuous Improvement (CI)

• Drive Kaizen, Continuous Improvement, and Operational Excellence programs.
• Facilitate improvement workshops and problem-solving sessions.
• Identify opportunities for productivity enhancement and process optimization.
• Implement best practices and standardization across operations.

3. Process Improvement & Waste Reduction

• Identify and eliminate the 8 wastes (Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, and Underutilized Talent).
• Improve material flow, process efficiency, and plant layouts.
• Lead Value Stream Mapping (VSM) exercises and improvement projects.
• Reduce cycle time, lead time, and non-value-added activities.

4. Lean Tools Implementation

• Drive implementation of:
• 5S
• Kaizen
• TPM (Total Productive Maintenance)
• SMED (Single Minute Exchange of Dies)
• Poka-Yoke
• Kanban
• JIT (Just-In-Time)
• Visual Management
• Root Cause Analysis
• Standard Work
• Six Sigma methodologies

5. Productivity & Cost Improvement

• Lead cost reduction initiatives through process improvements.
• Improve Overall Equipment Effectiveness (OEE).
• Increase labour productivity and machine utilization.
• Support capacity enhancement projects without significant capital expenditure.

6. Quality Improvement

• Work closely with Quality and Production teams to reduce defects and rework.
• Promote zero-defect manufacturing practices.
• Lead problem-solving initiatives using tools such as 8D, Fishbone Analysis, 5 Why, and PDCA.

7. Training & Culture Development

• Develop Lean capabilities across the organization.
• Conduct Lean awareness and certification programs.
• Mentor managers, engineers, supervisors, and shop-floor employees.
• Foster a culture of continuous improvement and employee engagement.

8. Performance Monitoring

• Define and track Lean KPIs.
• Prepare and present monthly operational excellence reports.
• Benchmark performance against industry standards and best practices.

9. Cross-Functional Collaboration

• Work closely with Production, Quality, Supply Chain, Engineering, Maintenance, HR, and Finance teams.
• Support new product introduction and process improvement projects.
• Drive organization-wide improvement initiatives.

Key Performance Indicators (KPIs)

• Overall Equipment Effectiveness (OEE)
• Productivity Improvement (%)
• Cost Savings Achieved
• Manufacturing Cycle Time Reduction
• Lead Time Reduction
• Inventory Reduction
• Defect Rate / PPM Reduction
• 5S Audit Scores
• Number of Kaizen Implemented
• Employee Participation in CI Activities
• On-Time Delivery Performance
• Scrap and Rework Reduction

Educational Qualifications

• Bachelor's Degree in Mechanical, Production, Industrial, Manufacturing, or related Engineering discipline.
• Lean Six Sigma Black Belt or Master Black Belt certification preferred.
• Certification in MOST application 

Experience

• 3–5 years of manufacturing experience.
• Experience in automotive, engineering, genset manufacturing, heavy engineering, capital equipment, or industrial manufacturing preferred.
• Proven track record of delivering measurable productivity and cost improvements.

Required Competencies

Technical Competencies

• Lean Manufacturing
• Six Sigma
• TPM
• Value Stream Mapping
• Kaizen Facilitation
• Industrial Engineering
• Process Optimization
• Statistical Analysis
• Project Management
• MOST

Behavioural Competencies

• Strategic Thinking
• Leadership & Team Development
• Change Management
• Problem Solving
• Influencing Skills
• Stakeholder Management
• Results Orientation
• Communication & Presentation Skills

Desired Outcomes

• Establish a sustainable Lean culture across the organization.
• Achieve significant productivity gains and cost reductions.
• Improve quality, delivery, safety, and operational performance.
• Develop internal Lean champions and continuous improvement capabilities.
• Drive world-class manufacturing practices and operational excellence.