Senior Engineer – VSM & Material Flow

• Purpose: The Sr. Engineer - Value Stream Mapping (VSM) & Material Flow will be responsible for driving continuous improvement initiatives by executing high impact VSM projects primarily on material flow for multiple value streams. This role will focus on implementing Single Piece Flow by designing, and sustaining pull-based production systems (Kanban, supermarket, JIT) to optimize flow, reduce inventory, and improve responsiveness to customer demand. Also tracking improvements through the generation and analysis of Value Stream Improvement Plans (VSIPs). The goal is to support the organization in achieving operational efficiency and process excellence.

• Conduct Value Stream Mapping (VSM):

• Collect relevant data for each defined value stream.

• Conduct VSM sessions/workshops to analyze current state, identify inefficiencies/kaizen bursts, and create an entitlement and future state roadmap for improvements.

• Target Box score improvements and enable accomplishments

Analyze And Implement VSIPs

• Analyze the generated Value Stream Improvement Plan (VSIPs) and prioritize for implementation.
• Work with cross-functional teams to ensure effective implementation of VSIPs with a focus on achieving Single Piece Flow.

Design and implement effective PULL systems

• Design and deploy Kanban systems (card-based, e-Kanban, hybrid models)
• Establish supermarkets, FIFO lanes, and replenishment loops
• Define inventory levels, buffer strategies, and replenishment signals
• Align pull system with customer demand and takt time.

Production Planning and Control integration

• Integrate pull system with ERP/MRP systems
• Convert push-system scheduling into demand driven replenishment
• Define heijunka (production leveling) strategies
• Coordinate with planning, procurement and logistics teams to optimize inventory

Data analysis and system calibration

• Calculate and maintain Kanban quantities, reorder points and safety stock levels
• Use data analytics for demand variability analysis, cycle time and lead time improvement and tracking
• Continuously optime the inventory towards reaching the single piece flow

Track And Report Progress

• Track the progress of VSIPs, ensuring the closure rate to meet the target of 80-90%.
• Track the Lead time and specific Pull system metrices
• Collect data and generate weekly Box Scores for each value stream (6 Box Scores per week).
• Ensure that all metrics are up to date and accurately reflect the performance of each value stream.

Document And Sustain Improvements

• Document all improvements and changes made during the VSM process.
• Implement measures to sustain improvements over time, ensuring long-term efficiency and effectiveness.

Collaboration And Stakeholder Engagement

• Work closely with cross-functional teams (Operations, Production, Quality, etc.) to implement changes and ensure alignment with business goals.

• Provide guidance and training on VSM principles and best practices to relevant stakeholders

• Qualifications:

Education: Bachelor’s degree in Industrial Engineering, Production Engineering, Mechanical Engineering

Experience

• Minimum of 3-5 years of experience in value stream mapping, process optimization, or lean manufacturing.
• Strong Expertise in Pull system, Heijunka /load levelling and Just in Time design and implementation.

Skills

• Strong analytical and problem-solving skills.
• Proficient in data collection, analysis, and reporting.
• Familiarity with Lean tools and techniques (e.g., Kaizen, 5S, Value Stream Mapping).
• Excellent communication and collaboration skills.
• Ability to manage multiple priorities and work independently

Lean Projects

• Experienced in executing Lean Improvement projects like Line Balancing & Cycle time optimization
• AutoCAD or similar software for Layout change to improve material flow.
• Power BI (optional) for transactional flow improvement projects