Lean Consultant - TPM

Role: Lean Consultant

Working days: Monday to Saturday

Role Description : -

• • Assess the current maintenance culture, equipment health, and OEE levels at the client facility.
• • Design and deploy a structured TPM roadmap covering all eight pillars across the organization.
• • Lead Autonomous Maintenance (AM) step-wise implementation with operators on the shop floor.
• • Establish Planned Maintenance systems including PM schedules, predictive maintenance indicators, and MTBF/MTTR tracking.
• • Drive Focused Improvement (Kobetsu Kaizen) activities to eliminate chronic equipment losses.
• • Implement Quality Maintenance standards to achieve zero-defect conditions through equipmentquality linkage.
• • Integrate Safety, Health & Environment (SHE) pillar into daily TPM routines.
• • Extend TPM practices to administrative functions through Office TPM initiatives.
• • Build internal TPM champions and conduct structured capability-building programs for operators, supervisors, and engineers.
• • Govern TPM steering committee reviews and report pillar-wise progress to client leadership.
• • Design and maintain TPM scorecards, visual pillar boards, and sustenance mechanisms.

Desire Candidate Profile:

• • In-depth working knowledge of all eight pillars of TPM with hands-on deployment experience.
• • Strong expertise in OEE measurement, loss tree analysis, and equipment reliability improvement.
• • Data-driven approach to problem-solving and root cause analysis.
• • Excellent communication and client-facing skills with the ability to influence without authority.
• • Strong follow-up skills and ability to sustain improvements post-implementation.
• • Effective stakeholder management and client relationship skills.
• • Flexible for extensive on-site travel across client locations.
• • Knowledge of maintenance management systems (CMMS), production planning, and inventory management.
• • Ability to independently govern TPM pillar teams and drive cross-functional engagement.
• • Basic understanding of composites manufacturing or similar industrial environments is an advantage.

Job Requirements:

• • Bachelors / Masters Degree in Mechanical, Industrial, or Production Engineering or a related field.
• • 4 to 8 years of relevant experience in TPM implementation and manufacturing / industrial consulting.
• • Demonstrated track record of independently governing end-to-end TPM programs in previous organizations.
• • Lean Six Sigma certification Black Belt preferred.
• • TPM Practitioner / Facilitator Certification from a recognized body (JIPM, CII, or equivalent) is highly desirable.
• • Proficiency in all eight pillars of TPM: Autonomous Maintenance, Planned Maintenance, Focused Improvement, Quality Maintenance, Early Equipment Management, Education & Training, Safety-Health-Environment, and Office TPM.
• • Strong knowledge of Lean and CI tools: Kaizen, 5S, VSM, SMED, Poka-Yoke, Standard Work, Visual Management, Kanban, FMEA, PM Analysis, Why-Why Analysis.
• • Experience with OEE tracking, loss elimination, and equipment reliability frameworks (MTBF, MTTR, PdM).
• • Prior experience in composites, plastics, automotive, or process industries is a strong advantage.
• • Outstanding facilitation, coaching, and problem-solving skills at all organizational levels.
• • Must be self-directed, well-organized, and possess strong follow-up discipline.
• • Excellent written, oral communication, and presentation skills.
• • Solid proficiency in MS Office applications; familiarity with CMMS tools is a plus.

Benefits:

• • Insurance coverage of Rs. 5,00,000/- for employees. For this no deductions are made from salary.
• • Every employee will have access to their respective insurance policy over an online platform which includes few other benefits such as: telehealth, wellness, unlimited dental consultations, free vision check-up, discounted health check-up & discounted medicines.
• • Work related travel is covered by the Company at all locations.
• • The HR team organizes virtual Meet & Learn sessions where team mates conduct presentations on topics related to projects or lean management for the benefit of the whole team.
• • Free Annual Health Check-up for Gemba employees & the same for discounted rate for family members.
• • E-counselling Partner: Providing unlimited free therapy sessions, organizing mindfulness sessions and webinar as well.