Assistant General Manager / Deputy General Manager – Manufacturing Excellence

Job Description – Deputy General Manager (DGM) – Manufacturing Excellence

Position:	Assistant General Manager / Deputy General Manager – Manufacturing Excellence
Location:	Faridabad, Haryana
Department:	Manufacturing Operations
Reporting To:	Chief Manufacturing Head

Position Summary

The AGM / DGM – Manufacturing Excellence will be responsible for driving operational excellence, productivity enhancement, cost optimization, quality improvement, and digital transformation initiatives across the fasteners manufacturing business. The role will lead Lean Manufacturing, TPM, Six Sigma, Industrial Engineering, and Continuous Improvement programs to achieve world-class manufacturing standards. The incumbent will act as a strategic partner to plant leadership in building a high-performance manufacturing culture focused on safety, quality, delivery, cost, and people development.

Key Responsibilities

1. Manufacturing Excellence Strategy

• Develop and deploy the Manufacturing Excellence roadmap aligned with business objectives.
• Establish a culture of continuous improvement across all manufacturing functions.
• Drive operational excellence initiatives to improve plant competitiveness and profitability.
• Benchmark plant performance against industry best practices and world-class manufacturing standards.

2. Lean Manufacturing & Continuous Improvement

• Lead enterprise-wide implementation of Lean Manufacturing methodologies.
• Drive Kaizen, Value Stream Mapping (VSM), 5S, SMED, Visual Management, and Waste Elimination programs.
• Facilitate continuous improvement projects across production, maintenance, quality, supply chain, and support functions.
• Institutionalize a structured problem-solving culture throughout the organization.

3. TPM (Total Productive Maintenance) Deployment

• Lead TPM implementation and maturity enhancement across manufacturing facilities.
• Drive improvement in Overall Equipment Effectiveness (OEE), machine reliability, and equipment utilization.
• Support Autonomous Maintenance and Planned Maintenance pillars.
• Develop systems for monitoring TPM performance and sustainability.

4. Productivity & Industrial Engineering

• Lead productivity improvement initiatives through work-study, time-motion studies, and line balancing.
• Improve labor productivity and optimize resource utilization.
• Identify bottlenecks and drive debottlenecking projects.
• Establish productivity benchmarks and monitor performance against targets.

5. Cost Optimization & Value Engineering

• Identify opportunities for manufacturing cost reduction and margin improvement.
• Lead value engineering and value analysis initiatives.
• Drive projects related to energy conservation, material yield improvement, scrap reduction, and process optimization.
• Monitor and track financial benefits realized from improvement projects.

6. Quality Excellence

• Partner with Quality teams to improve First Pass Yield (FPY), reduce defects, and strengthen process capability.
• Promote Six Sigma and data-driven quality improvement initiatives.
• Drive root cause problem-solving methodologies such as 8D, A3, Why-Why Analysis, and DMAIC.
• Support customer audit readiness and compliance initiatives.

7. Digital Manufacturing & Industry 4.0

• Drive manufacturing digitization initiatives and smart factory transformation.
• Implement digital dashboards and real-time performance monitoring systems.
• Promote data analytics for decision-making and performance improvement.
• Evaluate and deploy automation and Industry 4.0 technologies.

8. Performance Management & Governance

• Establish manufacturing performance management systems and review mechanisms.
• Develop KPI dashboards for Safety, Quality, Delivery, Cost, Productivity, and Morale.
• Conduct regular performance reviews with plant leadership.
• Ensure sustainability of implemented improvements through governance and audits.

9. Capability Building & Change Management

• Develop organizational capability in Lean, TPM, Six Sigma, and Operational Excellence tools.
• Design and conduct training programs for managers, engineers, and shop-floor employees.
• Mentor improvement champions and cross-functional project teams.
• Drive cultural transformation initiatives supporting operational excellence.

10. Cross-Functional Collaboration

• Collaborate with Manufacturing, Maintenance, Process Engineering, Quality, Supply Chain, HR, and Finance teams.
• Lead cross-functional improvement projects with measurable business impact.
• Support greenfield, brownfield, and expansion projects from an operational excellence perspective.

Key Performance Indicators (KPIs)

• Overall Equipment Effectiveness (OEE) Improvement
• Productivity Improvement (%)
• Manufacturing Cost Reduction (%)
• Labor Productivity Improvement
• Scrap & Rejection Reduction (%)
• TPM Maturity Score
• Lean Project Savings (₹)
• Energy Consumption Reduction
• First Pass Yield (FPY) Improvement
• Kaizen Implementation Rate
• Continuous Improvement Savings Realization
• Digital Manufacturing Adoption Metrics

Educational Qualifications

• B.E./B.Tech in Mechanical, Production, Industrial, Manufacturing, Metallurgical, or related Engineering discipline.
• MBA/PGDM in Operations Management preferred.
• Certifications in Lean Manufacturing, TPM, Six Sigma Black Belt, Operational Excellence, or Industrial Engineering will be highly preferred.

Experience

• 15 – 20 years of experience in Manufacturing, Industrial Engineering, Manufacturing Excellence, Operational Excellence, Continuous Improvement, or Plant Operations.
• Minimum 5 years of experience leading Lean/TPM/Operational Excellence initiatives in a manufacturing environment.
• Experience in Fasteners, Automotive Components, Auto Ancillary, Forging, Cold Forging, Precision Engineering, or High-Volume Manufacturing industries preferred.
• Proven track record of delivering measurable productivity, quality, and cost improvement results.

Technical Competencies

• Lean Manufacturing
• TPM (Total Productive Maintenance)
• Six Sigma (Green Belt / Black Belt)
• Industrial Engineering & Work Measurement
• Value Stream Mapping (VSM)
• OEE Improvement
• Cost Reduction & Value Engineering
• Problem Solving Methodologies (DMAIC, A3, 8D)
• Manufacturing Analytics & KPI Management
• Industry 4.0 & Digital Manufacturing
• Project Management
• IATF 16949 & Operational Systems
• SAP/ERP Systems

Leadership & Behavioral Competencies

• Strategic Thinking
• Change Leadership
• Influencing & Stakeholder Management
• Cross-Functional Collaboration
• Analytical & Data-Driven Decision Making
• Innovation & Continuous Improvement Mindset
• Results Orientation
• Team Development & Coaching
• Communication & Presentation Skills
• High Ownership & Accountability

Preferred Industry Background

Fasteners, Automotive Components, Auto Ancillary, Cold Forging, Forging, Bearings, Precision Engineering, Metal Forming, Engineering Components, Industrial Manufacturing, and other high-volume discrete manufacturing industries.

This document is for informational purposes only and is intended to provide a comprehensive overview of the desired qualifications and responsibilities associated with the role of Deputy General Manager (DGM) – Manufacturing Excellence.