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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.
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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
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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
More Information
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Palani Selvaraj
Recruiter & Professional Consultant- Strategic leader offering over 14+ years of multicultural experience in spearheading entire functions of HR Operations, Talent Acquisition, Talent Development, Staffing, HR Consulting, Assessment, Training, and Operations & maintaining relations with different parties including govt. parties and others
- Experienced in representing Company before Govt. Authorities like the Factory Inspectorate, Addl. Labor Commissioner, Govt. Labor Officer, PF & ESIC Authorities, LWF Authorities, District Magistrates, and Police Department. Affiliated with National HRD Network (NHRD), ISTD, NIPM, SHRM, CII & EFSI
Recognized as a key resource with strong operations & business skills with excellence in developing tools for recruitment and assessment for analyzing competencies and profiling; acquired business-aligned HR/ER acumen to meet the deliverables of the organization with a workforce of more than 1000 - Drove entire functions of talent acquisition, training & development, coordinating with the HR & development team; introduced numerous employee engagements activities and Implemented strategies like restructuring pay package, and HR care, and improving the employee retention rate also reduced apprentice attrition level by 60% through introducing innovative employee benefits & incentives (flex time & onsite day-care)
- Successfully managed direct & indirect teams simultaneously; set inspirational goals for the team, defined KPIs & metrics for the HR & Administration Team and ensured the achievement of the goals; collaborated with the senior level management team in the decision-making process; added value to the overall efforts of the organization in driving organizational objectives
Renukadevi Chandrasekar
Recruiter & Professional Consultant- An In-house Talent Acquisition professional with 1+ Yrs. of experience in Post recruitment.
- Experience in handling new joining on boarding processes and Personal File Management
- Supporting the recruitment team in hiring entry-level openings.
- Multilingual and trained to source in the Job portals
- Interested to explore the complete Recruitment Life Cycle.
Manikandan M
Recruiter & Professional Consultant- Senior HR with 8+ years of experience in end-to-end recruitment, specializing in sourcing and hiring highly skilled white-collar professionals across industrial, engineering, manufacturing, and IT functions.
- Experienced in strategic talent sourcing, candidate screening, and stakeholder management, with a strong track record in high-volume and niche skill hiring using advanced sourcing techniques and CRM/ATS platforms.
- Skilled in collaborating with hiring managers, driving workforce planning, and managing the complete hiring lifecycle including offer negotiation, on boarding, and talent retention to support organizational growth.
Bhuvaneswar V
Recruiter & Professional Consultant- Senior HR with 8+ years of experience in end-to-end recruitment, specializing in sourcing and hiring highly skilled white-collar professionals across industrial, engineering, manufacturing, and IT functions.
- Experienced in strategic talent sourcing, candidate screening, and stakeholder management, with a strong track record in high-volume and niche skill hiring using advanced sourcing techniques and CRM/ATS platforms.
- Skilled in collaborating with hiring managers, driving workforce planning, and managing the complete hiring lifecycle including offer negotiation, on boarding, and talent retention to support organizational growth.
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- A career ladder system, which defines the career progression path for employees based on their skills, experience, and length of service
- Integrated career progression framework with other processes in the organization as performance reviews, goals and OKRs, and promotion management.
- Internal Hiring – Advertising posts and promotion opportunities within the organization
- Providing employee development that readies workers for progression, such as training, coaching, mentoring, or involvement in special projects
- Regular Training Opportunities to develop skills at all levels
- Mentoring and Coaching schemes that give the individual’s the attention they need
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Remote Working
Medical Insurance
Life Insurance
Mental Well-being
Family Support and Care
Uniform
Paid Holiday
Learning Environment
Subsidised Healthy Meals
Work-Life Balance
Annual Health Check-ups
Teamwork
Safety and Working for the Community
Open and Transparent Culture
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Be curious
Researching our company will help you in your application and in subsequent rounds of interviews too. Find out about us and follow us on social media to know more about our company culture and values. It would be helpful for you to visit our website and know more about our products, people & processes. This will help you decide if a career with us is right for you, and ensure that you send in your application with relevant and correct information.
Complete the application
Every job has a specific set of requirements. In order to boost your chances of being hired, please send in a complete application with all supporting documents and information that is needed by our team. It is good to be accurate, truthful, and correct in your application. We would recommend that you review your application before sending it to us, and focus on quality of content rather than quantity of information.
Referrals
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Follow the instructions
This is the biggest application tip that we can give you: read the instructions thoroughly before you send the application over to us. Following the instructions correctly & fully will ensure that your resume goes through the hiring process smoothly and gets processed by the right person at the right time. It will increase your chance of being called for an interview and getting hired.
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Resume screening
Send in your resume with all the information required. We usually take 10 working days to look over the applications and arrive at a decision – we promise to let you know either way. If your resume is cleared, you move to the next stage in the recruitment process.
Preliminary meeting
This can take place via a video call or a phone call, or even a direct meeting. This preliminary meeting gives us the chance to get to know you more and to clear you for the next round of assessment.
Assessment round
In this round, you will go through a technical or a functional assessment depending on the role that you have applied for. There is also a DiSC assessment round for candidates who apply to us for key roles.
Final interview
If you have made it this far then you get to meet the team leaders or top management of our company – depending on the job that you have applied for. The final interview helps us understand you even more before we hire you for the job.
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Coimbatore is one of the major metropolitan cities in the Indian state of Tamil Nadu. It is surrounded by the Western Ghats mountain range to the west and the north, with reserve forests of the Nilgiri Biosphere Reserve on the northern side.
Coimbatore was rated as one of the safest cities in India for women, and a major hub for manufacturing, education and healthcare. It is also referred to as “the Pump City” as it supplies nearly 50% of India’s requirements of motors and pumps.