The Operational Excellence Manager will lead the site’s Lean transformation and continuous-improvement agenda across turbine and generator manufacturing operations. The role will improve safety, quality, delivery, cost, productivity, equipment effectiveness, and lead time through structured problem solving, standard work, value-stream improvement, daily management, and selective automation. Operational Excellence roles typically focus on eliminating losses, deploying Lean/Six Sigma methods, improving throughput and yield, and sustaining improvements through standardized processes and performance reviews.
This is a hands-on, shop-floor leadership role requiring deep engagement with heavy machining, fabrication and welding, assembly, and generator-component manufacturing team.
Function: Manufacturing / Operations
Location: Sanand, Ahmedabad (Gujarat)
Reports to: Operational Excellence Leader
Management level / band: LPB
Manufacturing scope
The role will support improvement across the full value stream, including:
Machining of turbine rotors, casings, diaphragms, and other major nuclear components.
Blade machining, inspection, handling, and preparation processes.
Heavy fabrication, welding, stress relieving (PWHT), blasting-painting, machining, and assembly of fabricated structures.
Turbine assembly, alignment, balancing, testing, and final inspection operations.
Generator parts manufacturing, including stator green bar production, insulation and processing operations.
Generator stacking, slotting, wedging, winding support, impregnation, and related assembly processes.
Material flow, tooling, fixtures, cranes, handling equipment, machine loading, and layout optimization.
Interface with Quality, Manufacturing Engineering, Maintenance, Planning, Supply Chain, EHS, and Production teams.
Key responsibilities
Lean transformation and daily management
Develop and deploy the site Operational Excellence roadmap aligned with plant safety, quality, delivery, cost, and productivity objectives.
Lead daily management systems, including SQDC boards, tiered meetings, escalation routines, visual management, and action follow-up.
Establish and monitor plant KPIs, including safety events and risks, quality performance, plan versus actual, schedule adherence, OEE, productivity, labor hours, lead time, 5S, TPM, and Kaizen effectiveness.
Conduct structured performance reviews with production, support, and cross-functional teams to identify gaps and drive corrective actions.
Ensure improvement actions are assigned, tracked, verified, and sustained through standardization.
Process improvement and waste elimination
Lead Value Stream Mapping for turbine and generator manufacturing value streams, identifying bottlenecks, waiting time, transport, inventory, rework, and non-value-added activities.
Conduct time studies, capacity analysis, line balancing, and cycle-time reduction studies for machining, welding, assembly, and generator-component operations.
Define and improve work methods, standard work, work instructions, process sequences, tooling requirements, and shop-floor controls.
Lead root-cause analysis and problem-solving reports (PSR/A3/8D as applicable) for recurring quality, productivity, delivery, and equipment issues.
Reduce changeover, setup, material-handling, inspection, and waiting losses through Lean methods such as SMED, 5S, Kanban, pull systems, and flow optimization.
Improve process repeatability, first-time quality, throughput, and on-time delivery while respecting product and process specifications.
Machining, welding, and assembly improvement
Partner with Manufacturing Engineering and Production teams to improve heavy machining processes for rotors, casings, diaphragms, and blades.
Analyze machine utilization, setup time, tool life, fixture changeover, inspection cycles, operator waiting, and material availability to improve machining output.
Support improvement of heavy fabrication and welding operations, including weld sequencing,…