Lead - Operational Excellence, Shirwal, ACG Capsules

Position Title: Engineer/Senior Engineer – Operational Excellence (Shirwal), ACG Capsules 

Organization Context 

ACG is the world’s only integrated pharma manufacturing solutions company. We are headquartered in Mumbai, India. ACG has a presence in over 100 countries with its products and services that strive to provide world-class technology across multiple domains. We offer a complete range of solutions beginning with empty capsules; granulation and tablet coating; capsule filling; tabletting; packaging films; blister packing and carton packing to the end-of-line solutions and track and trace systems. 

We have an opportunity in ACG Capsules / ACG Engineering / ACG Pharma Packaging / ACG Inspection.  

• Execute Continuous Improvement and Operational Excellence projects through structured data collection, analysis and implementation of sustainable actions. 

• Lead cross-functional teams in data collection, observation studies, trials and action planning to ensure timely delivery of CI projects. 

• Drive Lean Daily Management, Kaizen and change-management activities in line with the plant OpEx roadmap. 

• Build plant capability in Lean Six Sigma, problem solving, data analysis and continuous improvement practices. 

Strategic and planning 

• Support execution of the Plant Operational Excellence strategy and identify improvement opportunities. 

• Participate in improvement-area identification and execute agreed CI projects with defined targets and timelines. 

Functional – Core 

• Execute Lean Six Sigma, Kaizen and structured problem-solving projects and measure effectiveness against project outcomes. 

• Develop data collection plans and conduct GEMBA/observation studies, trials and process analysis using appropriate CI and statistical tools. 

• Apply RCA, Pareto, 5-Why, Fishbone, Cp/Cpk, MSA, VSM, SMED, DILO and Motion Study for process, quality, productivity and reliability improvement. 

• Coordinate with Manufacturing, Quality, Engineering and Maintenance teams for corrective actions and engineering solutions. 

• Drive Lean Daily Management System (LDMS), KPI reviews, action tracking and escalation routines. 

• Facilitate Kaizen, Poka-Yoke, Visual Management, Standard Work and shop-floor improvement activities. 

• Develop and maintain CI project dashboards and KPI reports using Excel and Power BI. 

• Support digitalization of shop-floor data collection and CI processes using Power Apps and other approved digital solutions. 

• Support Technical Training, Lean Six Sigma capability building, Small Group Activities / Quality Circles and CI events. 

• Support 5S audits and track improvement actions with process owners. 

Internal process 

• Monitor project progress, actions and risks and escalate delays or non-compliances to the Operational Excellence Manager and HODs. 

• Prepare project status, implementation and benefit updates for Plant Operational Excellence reviews. 

• Maintain CI project, Kaizen, LDMS and related documentation, trackers and closure records. 

People development 

• Train and coach associates and process owners in Lean Six Sigma, RCA, Kaizen, problem solving and Daily Management practices. 

• Support execution of the Technical Training Calendar and development of CI capability across the plant. 

• Support quarterly Kaizen events and Six Sigma project competitions for associates. 

• Continuous Improvement projects completed vs. planned and effectiveness against agreed targets 

• Processes standardized through CI projects, Standard Work, Visual Management and Poka-Yoke 

• Kaizen projects completed vs. planned 

• People trained as per the CI / Technical Training Calendar 

• LDMS / KPI review adherence and closure of improvement actions 

• 5S / GEMBA improvement actions completed vs. planned