Key Responsibilities:
Process Analysis & Optimization

• Analyze current production processes and identify waste (MUDA), bottlenecks, and improvement opportunities.
• Conduct time studies, cycle time measurements, layout analysis, and line balancing.
• Develop and implement optimized workflows in line with Lean Manufacturing principles.

Lean Tools Implementation

• Value Stream Mapping (VSM)
• 5S & Visual Management
• SMED (fast changeover)
• Kanban & Pull Systems
• Standard Work
• Poka-Yoke
• Lead Kaizen workshops and improvement events with cross-functional teams.

Performance Monitoring & KPI Improvement

• Monitor and improve KPIs such as: OEE, scrap rate, downtime, throughput, takt time, and lead time.
• Analyze root causes of deviations using RCA, 5 Why, Ishikawa, and DMAIC methodologies.

Support for New Products and Processes (NPI/NPP)

• Participate in the introduction of new equipment, new lines, and new products.
• Support PFMEA, control plan, and process validation activities.
• Optimize layout, manpower allocation, material flow, and logistics setup.
• Generate the local PBOM based on the PBOM received from HQ.
• Update PBOM data in the SIOP document and maintain accurate BOM information in Nexus ERP.
• Validate BOM consistency with routings, material consumption standards, and process requirements.
• Support engineering changes (ECR/ECO) by updating BOMs and related process documentation.

Cost Reduction & Efficiency Projects

• Identify cost reduction opportunities (materials, energy, labor, cycle time).
• Lead and implement continuous improvement projects delivering measurable results.
• Support maintenance and quality teams in improving machine reliability and reducing defects.

Training & Culture Development
Provide coaching and training to operators and engineers on Lean principles.
Promote a strong continuous improvement culture across the organization.
Ensure adherence to Lean standards and best practices within the plant.
Create, update, and maintain Standard Work Combination Sheets, detailed Work Instructions, and Operator Balance Charts to ensure process consistency, efficiency, and alignment with Lean standards
Material Flow & Industrialization Support
• Develop, implement, and maintain Kanban systems (internal and external).
• Create, print, and update Kanban cards and visual signals.
• Define and implement Kanban loops between production processes, supermarkets, and consumption points.
• Organize and perform labeling of racks, storage locations, production lines, and material zones.
• Support layout updates for material flow optimization and ensure proper floor marking and visual instructions.
• Collaborate with Logistics and Production teams to standardize and continuously improve material flow efficiency.