Operational Excellence

Job Purpose

To drive Operational Excellence initiatives across manufacturing, quality, engineering, supply chain, and support functions by implementing Lean Manufacturing and Six Sigma.

The role focuses on Reduction of Overall Opex Cost enhancing productivity, reducing waste, improving quality, ensuring compliance with cGMP requirements, and building a culture of continuous improvement across Zydus Lifesciences operations.

Key Responsibilities

Continuous Improvement & Lean Initiatives

• Lead Lean Manufacturing, Kaizen, Value Stream Mapping (VSM), and waste elimination projects.
• Identify opportunities for productivity enhancement, cycle time reduction, Yield improvement, QC Opex Cost reduction.
• Facilitate cross-functional improvement projects aligned with business objectives.
• Drive problem-solving methodologies such as DMAIC, PDCA, A3, Fishbone Analysis, and Root Cause Analysis (RCA).

Operational Excellence Programs

• Deploy Operational Excellence - SLIM frameworks across manufacturing and support functions.
• Monitor & Implement Cost Excellence projects via improvement in Overall Equipment Effectiveness (OEE), Right First Time (RFT), Yield, and Throughput.
• Standardize best practices and ensure sustainability of improvement initiatives.
• Develop and track Operational Excellence KPIs and dashboards.

Quality & Compliance

• Ensure all improvement initiatives comply with cGMP, regulatory requirements, and Zydus quality systems.
• Collaborate with Quality Assurance, Production, and Regulatory Affairs teams to strengthen compliance and process robustness.
• Support investigations, CAPA effectiveness assessments, and quality improvement programs.

Data Analytics & Performance Monitoring

• Analyze operational data to identify trends, bottlenecks, and improvement opportunities.
• Prepare management reports and present performance metrics to leadership teams.
• Utilize digital tools, automation, and data visualization platforms for performance tracking.

Training & Capability Building

• Conduct training programs on Lean, Six Sigma, Kaizen, 5S, TPM, Problem Solving, and Operational Excellence methodologies.
• Mentor employees and cross-functional teams in continuous improvement practices.
• Foster a culture of innovation, accountability, and operational excellence.

Cost Optimization

• Drive projects focused on:

• Manufacturing cost reduction

• Energy optimization

• Resource utilization improvement

• Inventory optimization

• Waste reduction

• Track savings and validate financial benefits from improvement projects.

Stakeholder Management

• Partner with Manufacturing, Engineering, Quality, Supply Chain, HR, and Finance teams.
• Present project updates and business impact to plant leadership and senior management.
• Support strategic transformation initiatives across business units.

Key Performance Indicators (KPIs)

• Productivity improvement (%)
• Cost savings achieved
• OEE improvement (%)
• Yield improvement (%)
• Lead time reduction (%)
• Employee engagement in CI activities

Educational Qualification

• B.Pharm / M. Pharm
• B.E./B.Tech (Chemical, Mechanical, Industrial, Production, Pharmaceutical Engineering)
• MBA/PGDM (Operations) preferred

Required Skills :

Technical Skills

• Lean Manufacturing
• Six Sigma (Green Belt/Black Belt preferred)
• TPM (Total Productive Maintenance)
• Value Stream Mapping
• Project Management
• Data Analytics & Dashboarding via Power BI / Tableau

Behavioural Competencies

• Strategic Thinking
• Problem Solving
• Leadership & Influencing Skills
• Stakeholder Management
• Change Management
• Decision Making
• Communication & Presentation Skills
• Cross-functional Collaboration

Preferred Certifications

• Lean Six Sigma Green Belt / Black Belt
• TPM Certification
• Lean Practitioner
• Project Management Certification (PMP preferred)
• Business Excellence / EFQM / Malcolm Baldrige exposure

Operational Excellence (OpEx) Intake Brief

Criteria

Years of Experience

7-17 years in Pharmaceutical Manufacturing, Engineering, Quality, Supply Chain, Continuous Improvement, Business Excellence, or Operational Excellence functions. Minimum 25 years of experience leading improvement projects and cross-functional initiatives.

Educational Qualification

B.Pharm / M.Pharm / B.E. / B.Tech (Chemical, Mechanical, Industrial, Production, Pharmaceutical Engineering). MBA/PGDM (Operations) preferred.

Basic Exposure Combination Required (Brief Description)

1. Exposure to pharmaceutical manufacturing operation (OSD, Injectable, API, Biologics, Vaccines, Specialty Products) OR FMCG manufacturing operation
2. Hands-on experience in Lean Manufacturing, Six Sigma, TPM, Kaizen, and Continuous Improvement initiatives.
3. Proven experience in productivity enhancement, cost optimization, yield improvement, OEE improvement, and waste reduction projects.
4. Exposure to cGMP-regulated manufacturing environment with cross-functional stakeholder management.
5. Experience in driving digital transformation, dashboarding, operational analytics, and performance management initiatives.

Key MUST HAVE Technical Skills (Max 5)

• Lean Manufacturing Implementation
• Six Sigma / DMAIC Project Execution
• TPM & OEE Improvement
• PDCA, A3 Problem Solving

Key GOOD TO HAVE Technical Skills (Max 5)

• Value Stream Mapping (VSM)
• Statistical Process Control (SPC)
• Digital Manufacturing / Industry 4.0 Exposure
• Business Excellence Frameworks (EFQM/Baldrige)

Key Digital / Operational Technology (OT) Skills

• Power BI / Tableau Dashboarding
• SAP (PP/MM/QM Modules)
• Manufacturing Analytics Tools
• Digital Performance Monitoring Systems
• Data Visualization & KPI Tracking Platforms