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Role Purpose
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To ensure that standards of production and working methodology are maintained and improved to deliver best practice in results of efficiency and labour utilization. Identify opportunities to improve the Indian operations in terms of throughput times, service and productivity enhancement to deliver World Class performance.
To support the manufacturing department and warehousing operations through the creation and implementation of clear, well defined IE standards that can be used to support the continuous improvement process.
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Principal Accountabilities and Key Activities
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Set & Manage Industrial Engineering Standards
- Ensure that IE standards of production and working methodology as per work measurement studies, provide zero base standards for every work center in manufacturing department.
- Ensure industrial engineering standards are developed and being applied within the manufacturing floor for both dyehouse and final winding with gaps identified, documented and communicated. A monthly report should be in place to document the gaps between the standard and the actual practice for each department. [head count, allocations].
- Work out Mhrs and Lhrs for all articles
- Work out manning requirement based on log plan for all work centers, circulate to all stake holders for their actions to trim the manning in line with Zero-base. Assist in the compilation and calculation of the P15 and Strategies to identify manning and capital expenditure requirements.
- Prepare OHK reconciliation report on monthly basis and narrow down the gap between Zero base Vs Actual.
- Generate GT reconciliation report to understand the details between system consumption and standard consumption. Take initiatives to monitor the GKG revision, performance on monthly basis.
- Develop timely and accurate reporting of relevant KPI’s and manufacturing monitoring
- Drive continuous improvement to maximise output in all manufacturing areas & Develop and Assist in implementation of continuous improvement initiatives.
- Support other managers in introducing new working methodology and procedures.
- Assist in Training of employees in correct working practices to deliver consistent excellence in performance.
- Improve working practices to achieve reduced material consumption through reduced wastage and non-conformity within the process.
- Roll out best practice I.E. and Lean Manufacturing concepts to other units to achieve pan-India improvement.
- Ensure effective communications are in place between departments to aid the change management process within the plant with a view to implementing best practice manning allocations in line with developed standards.
- Ensure the machine park is optimally laid out and can deliver high efficiency through good operator ergonomics and best practice allocations.
- Ensure clear SOPs are in place for the calculation of industrial engineering standards and that these are understood by the departmental managers.
- Using the S&OP data project the machine requirement (OEE), head count requirement, OHK and present this at the monthly OCM.
Drive & Manage Continuous Improvement Process
- Continually drive productivity and efficiency improvement through the adoption of A3 charter, LSS techniques, including DMAIC processes.
- Drive manufacturing productivity improvement ideas, quick hits, kaizen projects & LSS projects thereby achieve targeted numbers y-o-y.
- Ensure all new projects are entered on the Power Steering project management facility, taken from hopper ideas through to full projects that are monitored throughout the month and updated monthly in line with the group reporting requirements
- Ensure the integrity of all data used for the calculation of plant wide incentive schemes.
Activity Description
- Monitor attainment of the annual production plan
- Identify the internal factors, which may affect the attainment of production output.
- Review working methods in order to optimize them
- Analyze the organization of production in order to improve it
- Analyze the working time structure of machines
- Determines working time of the operations (rate setting)
- Audit the working norms compliance through production operators
- Calculate variations for future production plans, calculation of machine and Operator hours and therefore machine and labour utilisation
- Guides the multi-skill and training activity of operators in collaboration with the Trainer and Development Coordinator
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Education, Qualifications and Experience
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Essential
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Desirable
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Knowledge and Understanding of:
- Concepts about Time and Motion Studies, IMT/OMT, Element sheet workings.
- Dyesect reporting
- SAP PP Module [Reporting]
- Power BI (project creating and updating)
- Every Angle [Creating Queries]
- Different types of Coats threads and make ups
- Different machine types and running conditions
- Variables that effect and impact IE standards
- Superior Communication abilities.
- Excellent analytical skills.
- Experience in similar area.
- PC skills especially in database and spreadsheet applications.
- Knowledge or qualification in Lean Management Techniques.
- Minitab analysis.
- Data analysis using Statistical tool applications.
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Experience
- Professional graduate in the area of industrial/production engineering or similar areas in a science based discipline
- 7+ years of experience
- Minimum 3 years relevant work experience which include time and motion study
- Experience in conducting risk assessment and is JSA beneficial
- Experience in value stream mapping advantageous
- Must possess knowledge of Project management.
- Team management experience- Local legislation for worker routines, incentive pay, work loading
- Understanding of factory wide incentive schemes and calculations
- Coats Health and Safety policies and procedures
- Knowledge of Coats operational SOP that influence IE standards
- Understanding of Lean Six Sigma tool box up to BB/MBB level. (Black Belt / Master Black Belt)
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Skills & Ability
- Proficient in the use of Microsoft tools
- Superior Communication abilities.
- Excellent analytical skills.
- Experience in similar area.
- Time management skills
- Train the train capability
- High level of attention to detail
- Proficient in both English with ability to interpret and translate documentation as required
- Good analytical skills
- Ability to lead and influence both teams and individuals
- Strong Presentation skill
- Ability to create and maintain action plans to under pin key objectives
- Knowledge or qualification- Lean Six Sigma Techniques’ BB/MBB
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