Manager - TPM; Operational Excellence

Position: Manager - TPM (Operational Excellence)
Position Summary
The TPM Person will be responsible for implementing and driving Total Productive Maintenance (TPM) practices across the plant to improve equipment effectiveness, reduce breakdowns, enhance safety, and foster a culture of continuous improvement. The role will work closely with Operations, Maintenance, Quality, and Safety teams to ensure optimal plant performance.

Location:

Asmoli, Mansurpur & Meerganj

Key Responsibilities
1. TPM Implementation & Governance
Lead deployment of TPM pillars:
Autonomous Maintenance (AM)
Planned Maintenance (PM)
Focused Improvement (Kaizen)
Quality Maintenance
Early Equipment Management
Safety, Health & Environment (SHE)
Training & Education
Office TPM
Develop TPM roadmap and ensure milestone-based execution.
Establish TPM standards, SOPs, and audit mechanisms.

2. Equipment & Process Reliability
Improve OEE (Overall Equipment Effectiveness), availability, performance & quality.
Mean Time between Failure (MTBF), Mean Time to Repair (MTTR)
Reduce breakdowns, minor stoppages, defects, and losses.
Analyse equipment failures using RCA, FMEA, and Pareto analysis.
Coordinate with maintenance teams for preventive & predictive maintenance planning.

3. Continuous Improvement & Kaizen
Drive Kaizen projects and cross-functional improvement initiatives.
Facilitate small group activities (SGA), quality circles, and improvement workshops.
Track cost savings, productivity gains, and operational efficiencies.

4. Training & Culture Development
Train plant employees on TPM concepts, AM steps, 5S, and continuous improvement tools.
Build TPM ownership among operators and maintenance personnel.
Develop skill matrices and competency enhancement plans.

5. Safety, Quality & Compliance
Integrate TPM with safety and quality systems.
Ensure workplace organization using 5S & visual management.
Support ISO, food safety, and statutory compliance initiatives.

6. Performance Tracking & Reporting
Establish TPM KPIs and dashboards.
Conduct regular audits, gap assessments, and progress reviews.
Present TPM progress to plant leadership and management committees.

Educational Qualification & Experience
B.E./B.Tech – Mechanical / Electrical / Production / Industrial Engineering
Certification in TPM / Lean Manufacturing preferred
8-10 years of experience in manufacturing / sugar / process industry (4-5 years of relevant TPM implementation experience).
Proven track record in TPM deployment & plant performance improvement
Technical

Skills:

Strong working principles of mechanical, electrical, instrumentation, and control systems
High computer literacy
Ability to troubleshoot and diagnose technical issues with RCA.
SAP knowledge is an add-on advantage.

Soft Skills:

Exceptional leadership, communication, and interpersonal skills to manage diverse teams and stakeholders.
Strong analytical and problem-solving aptitude.
A results-oriented and pragmatic approach to project execution under tight deadlines.