Senior Manager - Operational Excellence

Perfetti Van Melle · India

Role Purpose

The Senior Manager – Operational Excellence will lead strategic and continuous improvement initiatives across manufacturing, supply chain, and operations, with a strong focus on productivity, quality, cost optimization, capacity utilization, and operational excellence.

The role will be responsible for:

• Driving Lean, Six Sigma and TPM initiatives to improve OEE and reduce operational losses.
• Leading cross-functional improvement projects aligned with business OGSM (Objectives, Goals, Strategies & Measures).
• Developing and implementing the Continuous Improvement strategy, governance, and operating rhythm.
• Building problem-solving capabilities across teams and coaching operational leaders.
• Monitoring key operational KPIs and providing actionable insights to senior leadership.
• Leading Value Engineering, Capacity Optimization, Line Balancing, and Digital Transformation initiatives.
• Strengthening the overall culture of continuous improvement and data-driven decision-making across the plant.

Key Responsibilities

1. Daily Management System

• Lead and strengthen the Daily Management System – POS across the plant.
• Drive adherence to POS standards and routines across functions.
• Identify and close gaps emerging from POS audits, ensuring achievement of target scores.
• Support plant leadership in establishing a strong performance management and review cadence.
• Use daily management data to identify performance gaps and prioritize improvement opportunities.

2. Problem Solving & Continuous Improvement

• Lead Root Cause Analysis (RCA) initiatives and support production teams in improving OEE and eliminating chronic losses.
• Drive structured problem-solving using Lean Six Sigma, statistical tools, and data-driven methodologies.
• Train and coach operators and teams
• Develop an appreciation of the S&OP process and its linkage with operating hours, capacity utilization, and production planning.
• Lead and deliver cross-functional statistical improvement projects.
• Coach project managers and operational teams in structured problem-solving and project execution.
• Lead programs and manage portfolios of improvement initiatives across functions.
• Conduct Value Stream Mapping (VSM) and Line Balancing to identify and address chronic operational issues.
• Identify opportunities to improve productivity, reduce waste, optimize costs, and enhance quality.

3. Capability Development

• Mentor teams and build organizational capability in Continuous Improvement, Lean Six Sigma, and structured problem-solving.
• Develop and execute capability-building programs through the LSS Calendar cycle.
• Conduct skill assessments of operators and identify capability gaps.
• Lead targeted improvement and training programs to close identified capability gaps.
• Build a strong pipeline of internal CI champions and problem-solving practitioners.

4. Capacity Planning & Budgeting

• Develop a strong understanding of Capacity Planning and OEE Loss Trees and their linkage to short-term and long-term factory budgeting.
• Support capacity optimization initiatives based on demand, operating hours, OEE, and available resources.
• Develop an understanding of and contribute to budgeting processes related to:
• Energy
• Labour
• Maintenance
• Repairs
• Operational efficiency
• Identify opportunities to improve cost efficiency through productivity and operational improvement initiatives.
• Work collaboratively with multiple departments and functions to align operational improvement priorities with business requirements.

5. Digitization & Industry 4.0

• Lead Industry 4.0 and manufacturing digitization initiatives across the plant.
• Develop a strong understanding of the automation pyramid and its application within manufacturing environments.
• Identify opportunities to digitize manual processes, reports, and performance-monitoring systems.
• Lead small- to medium-scale digitization projects related to manufacturing reporting and operational performance.
• Leverage data and digital tools to improve visibility, decision-making, and operational efficiency.

Qualifications & Certifications

Educational Qualifications

• Bachelor’s degree in Engineering or a related technical discipline.
• Master’s degree preferred.

Certifications

• TPM Expert / Black Belt Certification from a recognized institution/body such as ASQ, JIPM, or equivalent.
• Lean Six Sigma certification preferred.

Experience

• 8–12 years of overall professional experience.
• Minimum 4–5 years of experience in FMCG / manufacturing environments, preferably in an Operational Excellence / Continuous Improvement role.
• Proven experience in leading Continuous Improvement programs and cross-functional teams.
• Demonstrated experience in driving measurable improvements in OEE, productivity, cost, quality, capacity utilization, and operational performance.
• Experience in leading multiple improvement projects/programs simultaneously.