Operating Advisor - Lean Specialist

Operating Advisor – Lean Specialist

Lean Systems Engineering is a management process where the focus is primarily to improve the overall client value and carry out various activities to achieve the best results. The Lean Systems Specialist will play a crucial role in ensuring that efficiency is increased by eliminating waste and considering what will matter rather than blindly accepting the existing ideas and practices. They work with subordinates to develop and initiate a program that will close the gaps that have been identified, thus enhancing the productivity and quality standards.

Key Responsibilities of a Lean Systems Specialist

A Lean Systems Specialist is responsible for improving operational systems and efficiency. They are responsible for overseeing operations and reducing waste. They are also responsible for making production operations error free by designing quality controls into the process. Additionally, they are responsible for designing and planning the production operation process.

The Lean Systems Specialist is responsible for leading and deploying the best practices in the organization by taking initiative to support continuous improvement in various processes by reducing the tooling costs, improving the flow of material, and setting up cycle times. They work towards achieving the manufacturing goals and objectives of the organization. They lead, facilitate, execute, and manage projects to reduce the costs significantly by implementing Lean, WCP, and Six Sigma tools and methodologies. They use their expertise to identify and recommend improvements by applying the relevant principles. To better understand the responsibilities and duties that are shouldered by this professional, listed below are some points that will help you in providing valuable guidance:

• To make optimum utilization of Lean Systems and Six Sigma tools to assist in preparing the feasibility studies and ensure that the costs incurred are justified.
• To evaluate various improvements, create value analysis and to look out for ways to reduce the costs in the engineering and operations functions.
• To confer with the senior and other related personnel to create designs and resolve any relevant issues.
• To give directions to help in preparing the layouts and detailed drawings that will eventually assist in improving the operational processes.
• To develop methods that would help in reducing cost without compromising quality standards to ensure increased efficiency.
• To achieve cost effective designs and to carry out research, design, and development work of the operational process that would include assembly methods, production flow, production equipment and IT systems.

In addition to the above responsibilities, this professional helps in preparing and maintaining the detailed layouts, designs, and test plans. They also prepare cost justification for various tools, equipment, machinery, and IT systems that may be required for various processes. They review the operational areas for potential safety hazards and make sure that all the safety practices are being followed while implementing the new processes. They train the supervisors and operators to incorporate quality checks and balance the workflow to increase productivity.

They help in determining the root causes for system inefficiencies and failures and make recommendations for changes in designs and related processing methodologies. They identify the key areas for improving these standards and incorporate new techniques to enhance the existing operating standards. They are responsible for training and mentoring the new staff personnel and supervising other team members. They are involved in preparing the documentation for the improved processes and ensure that the product designs are up to standard levels.

Essential Skills and Abilities

To make a successful career in the field of lean engineering, an individual should be adaptable to accepting new changes in the field of lean systems and should remain abreast of the latest developments in that field. They should be extremely well organized and should have the ability to identify problems and resolve them quickly. Strong oral and written communication skills with excellent organizational, planning and implementation skills would prove to be an advantage. They should be self-driven with a positive attitude and should be results oriented. Excellent analytical skills combined with good negotiation and conflict management skills with proficiency in computers would be beneficial.

Educational Background

To qualify for this position, it is necessary that a person should have completed a bachelor's degree in engineering. A demonstrated working knowledge of Lean/Six Sigma in the manufacturing/operations field with good project management skills would prove to be a huge plus. The individual who has completed formal training in Lean/Six Sigma will be preferred and have an edge over the rest of the candidates.

POSITION QUALIFICATIONS

• B.S. in Industrial Engineering or closely related engineering discipline
• Lean Black Belt and Six Sigma Black Belt certification is preferred.
• Minimum 6 years of applicable work experience in a manufacturing/Distribution environment.
• Familiar with Structured problem solving to effectively lead problem investigation and resolution.
• Working knowledge on a wide range of:
• 5S
• Andon
• Bottleneck Analysis
• Continuous Flow
• Gemba (The Real Place)
• Level Scheduling
• Policy Deployment
• Autonomation
• Just-In-Time (JIT)
• Lean tools, such as Continuous Flow, Heijunka, Kanban, Standardized Work and Takt Time.
• Kaizen (Continuous Improvement)
• Kanban (Pull System)
• KPIs
• Muda (Waste)
• Overall Equipment Effectiveness (OEE)
• PDCA (Plan, Do, Check, Act)
• Poka-Yoke (Error Proofing)
• Root Cause Analysis
• Single-Minute Exchange of Dies (SMED)
• Reduce setup (changeover) time to less than 10 minutes. Techniques include:
• Six Big Losses
• SMART Goals
• Standardized Work
• Takt Time
• Total Productive Maintenance (TPM)
• Value Stream Mapping
• Visual Factory
• Able to use statistical analysis software in Excel or Minitab
• AutoCAD and SolidWorks proficiency preferred
• Good written and verbal communication, as well as solid presentation and facilitation skills
• Proficiency with Microsoft Suite; including Excel, PowerPoint, Word, Visio

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