Manager – Lean Manufacturing & Operational Excellence

Greetings from Synergy Resource Solutions (www.synergyresource.co.in), a leading HR Consultancy firm & Career Guide for Professionals like you. We are hiring for one of our leading clients.

Client: One of India’s largest and most advanced toy manufacturers, offering a wide range of products across categories like plastic toys, electric toys, STEM toys, silicone toys, and wooden toys. Serving over 180 distributors, 8,000+ retail stores, and leading e-commerce platforms, they are now expanding into premium baby products and exploring global markets. 

Job Title - Manager - Lean Manufacturing & Operational Excellence

Working days and timings - 9.15 AM - 6:45 PM

Location - Rajkot

Experience: - 10-15 years 

Qualification - Any Graduate

Salary: ₹80,000 to 1,00,000/Month

Purpose of the Role

(Designated for developing manufacturing systems, operational discipline, and continuous improvement culture)
To establish and drive Lean Manufacturing, operational discipline, process standardization, and continuous improvement initiatives across the plant by implementing structured systems, improving productivity, reducing waste, and developing a culture of operational excellence.

Role Objective (Very Important)

SHOULD become:

• Execution-focused improvement leader

• System implementation driver

• Shop-floor transformation coordinator

• Cross-functional improvement catalyst

Should NOT become:

• Reporting-only person

• Audit-only person

• Consultant-type presentation maker

Key Responsibilities

A. Lean Manufacturing Implementation

• Drive implementation of Lean Manufacturing principles across all departments

• Identify and eliminate wastes (Muda) in processes

• Improve productivity, flow efficiency, and process discipline

• Conduct Kaizen activities and continuous improvement initiatives

• Support line balancing and process optimization

B. 5S & Visual Management

• Implement and sustain 5S culture across plant

• Develop visual controls, display boards, and workplace organization systems. Conduct regular 5S audits

• and improvement tracking. Improve workplace discipline and shop-floor visibility

C. SOP / Process Standardization

Develop and standardize:

• SOPs, Work Instructions (WI), Checklists, Formats, Process flow charts,

• Ensure process adherence through monitoring and training

• Establish basic operational controls

D. Data Monitoring & Reporting

• Develop daily/weekly/monthly monitoring systems

• Create dashboards for:

• Rejection, Productivity, Downtime, OEE, Rework, Delivery performance.

• Improve data visibility for decision-making

E. Root Cause Analysis & Problem Solving

Lead structured RCA activities using:

• 5 Why, Fishbone Diagram, Pareto Analysis.

• Track CAPA implementation

• Reduce recurrence of process issues

F. Cross-Functional Coordination

Work closely with:

• Production, Quality, Maintenance, Stores, Dispatch

• Coordinate implementation of improvement initiatives

• Ensure alignment between departments

• G. Training & Awareness Development

Conduct basic awareness training on: Lean concepts, 5S, SOP adherence, Process discipline, Problem-solving

Develop continuous improvement culture among employees

H. Audit & Compliance Support

Support implementation readiness for:

ISO systems, Internal audits, Customer audits

Ensure documentation discipline

Key Deliverables / KPIs:

• Reduction in rejection/rework %

• 5S audit score improvement

• SOP implementation status

• Number of Kaizen implemented

• Downtime reduction

• Productivity improvement

• Closure of RCA / CAPA

• Improvement project completion

• Visual management implementation

• Data reporting accuracy & timeliness

Required Skill Set
Technical Skills:
 Lean Manufacturing
 5S implementation
 Kaizen
 RCA tools
 Visual management
 Process mapping
 SOP development
 Basic Industrial Engineering concepts
 Data analysis & reporting
 Six Sigma
 OEE monitoring
 TPM basics
 ISO systems
 Manufacturing process improvement

Required Experience :

• 8-10 years experience in manufacturing improvement / operational excellence

• Experience in factory setup improvement or system implementation preferred

• Hands-on shop-floor implementation exposure mandatory

Educational Qualification :

B.E / B.Tech / M.Tech (Mechanical / Production / Industrial / Manufacturing) & Lean Six Sigma certification mandatory.

Personality Expectations (Very Important):

The candidate must:

• Be execution-oriented

• Work on shop floor

• Drive discipline

• Influence teams

• Take ownership of implementation

• Be comfortable in developing systems from basic level

Reporting Structure :

• Direct reporting to Operations Head / Directors

• Functional coordination with QA Head & Core members.

What We Offer:

• A chance to shape the online identity of one of India’s most exciting toy brands.
• Freedom to experiment with fresh ideas and formats.
• A vibrant, collaborative team and a culture of innovation.
• Competitive salary and growth opportunities

If your profile is matching with requirement & if you are interested for this job, please share your updated resume with details of your present salary, expectations & notice period.