{"id":3684971,"url":"https://alion.io/job/arabelle-solutions-operational-excellence-manager","title":"Operational Excellence Manager","company":{"id":2467342,"name":"Arabelle Solutions","domain":"arabellesolutions.com","url":"https://alion.io/company/arabellesolutions","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Workday","truth_index":{"grade":"A","score":87,"open_postings":87,"ghost_share":0,"stale_share":0.517,"repost_share":0,"time_to_fill_p50_days":53,"computed_at":"2026-11-05T05:54:30Z"}},"role":"Operations","role_family":"Operations","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Sānand, India"],"countries":["IN"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":null,"experience_years_min":7,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Kanban","optional":false},{"name":"Machine Learning","optional":false},{"name":"Microsoft Excel","optional":false}],"status":"live","first_seen_at":"2026-11-03T14:35:59Z","employer_posted_date":"2026-11-03","last_verified_at":"2026-11-05T17:25:41Z","board_verified":true,"closed_at":null,"days_open":2,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":2},"description":"The Operational Excellence Manager will lead the site’s Lean transformation and continuous-improvement agenda across turbine and generator manufacturing operations. The role will improve safety, quality, delivery, cost, productivity, equipment effectiveness, and lead time through structured problem solving, standard work, value-stream improvement, daily management, and selective automation. Operational Excellence roles typically focus on eliminating losses, deploying Lean/Six Sigma methods, improving throughput and yield, and sustaining improvements through standardized processes and performance reviews.This is a hands-on, shop-floor leadership role requiring deep engagement with heavy machining, fabrication and welding, assembly, and generator-component manufacturing team.\nFunction: Manufacturing / Operations\nLocation: Sanand, Ahmedabad (Gujarat)\nReports to: Operational Excellence Leader\nManagement level / band: LPB\nManufacturing scope\nThe role will support improvement across the full value stream, including:\nMachining of turbine rotors, casings, diaphragms, and other major nuclear components.\nBlade machining, inspection, handling, and preparation processes.\nHeavy fabrication, welding, stress relieving (PWHT), blasting-painting, machining, and assembly of fabricated structures.\nTurbine assembly, alignment, balancing, testing, and final inspection operations.\nGenerator parts manufacturing, including stator green bar production, insulation and processing operations.\nGenerator stacking, slotting, wedging, winding support, impregnation, and related assembly processes.\nMaterial flow, tooling, fixtures, cranes, handling equipment, machine loading, and layout optimization.\nInterface with Quality, Manufacturing Engineering, Maintenance, Planning, Supply Chain, EHS, and Production teams.\n\nKey responsibilities\nLean transformation and daily management\nDevelop and deploy the site Operational Excellence roadmap aligned with plant safety, quality, delivery, cost, and productivity objectives.\nLead daily management systems, including SQDC boards, tiered meetings, escalation routines, visual management, and action follow-up.\nEstablish and monitor plant KPIs, including safety events and risks, quality performance, plan versus actual, schedule adherence, OEE, productivity, labor hours, lead time, 5S, TPM, and Kaizen effectiveness.\nConduct structured performance reviews with production, support, and cross-functional teams to identify gaps and drive corrective actions.\nEnsure improvement actions are assigned, tracked, verified, and sustained through standardization.\nProcess improvement and waste elimination\nLead Value Stream Mapping for turbine and generator manufacturing value streams, identifying bottlenecks, waiting time, transport, inventory, rework, and non-value-added activities.\nConduct time studies, capacity analysis, line balancing, and cycle-time reduction studies for machining, welding, assembly, and generator-component operations.\nDefine and improve work methods, standard work, work instructions, process sequences, tooling requirements, and shop-floor controls.\nLead root-cause analysis and problem-solving reports (PSR/A3/8D as applicable) for recurring quality, productivity, delivery, and equipment issues.\nReduce changeover, setup, material-handling, inspection, and waiting losses through Lean methods such as SMED, 5S, Kanban, pull systems, and flow optimization.\nImprove process repeatability, first-time quality, throughput, and on-time delivery while respecting product and process specifications.\nMachining, welding, and assembly improvement\nPartner with Manufacturing Engineering and Production teams to improve heavy machining processes for rotors, casings, diaphragms, and blades.\nAnalyze machine utilization, setup time, tool life, fixture changeover, inspection cycles, operator waiting, and material availability to improve machining output.\nSupport improvement of heavy fabrication and welding operations, including weld sequencing, fit-up, distortion control, rework reduction, handling, and workflow design.\nImprove turbine assembly and generator stator manufacturing processes through better layout, kitting, sequencing, standard work, ergonomic design, and visual controls.\nIdentify opportunities to reduce lead time and work-in-process across long-cycle, high-value components.\nAutomation, ergonomics, and technology\nIdentify, evaluate, and implement cost-effective low-level automation, robotics, mechanized handling, digital tools, and assistive technologies.\nLead feasibility studies, benefit calculations, investment justifications, supplier coordination, pilot trials, and implementation for selected automation projects.\nApply human-factors and ergonomic principles to reduce manual effort, improve safety, and improve operator productivity in heavy-component handling and assembly areas.\nStay current with Industry 4.0, AI, machine learning, robotics, digital performance management, and relevant manufacturing technologies; assess practical applications for the site\nBuilding Capability and Culture\nTrain, coach, and develop production supervisors, engineers, operators, and cross-functional teams in Lean thinking, structured problem solving, standard work, 5S, TPM, and daily management.\nLead Kaizen events, improvement workshops, and cross-functional projects from diagnosis through implementation and benefit validation.\nCommunicate the Operational Excellence vision, expectations, and results across the plant.\nBuild a culture of ownership, data-based decision making, safety awareness, quality discipline, and continuous improvement.\nArea\nIndicative KPIs\nSafety\nEHS events, near misses, risk closure, ergonomic improvement actions\nQuality\nFirst-time right, rework, scrap, customer/internal complaints, process adherence\nDelivery\nPlan versus actual, schedule adherence, lead time, on-time completion\nProductivity\nOEE, machine utilization, output per labor hour, cycle time, variance and utilization\nCost\nCost-reduction savings, labor-hour reduction, rework reduction, inventory/WIP reduction\nLean maturity\n5S score, standard-work adherence, TPM effectiveness, Kaizen completion and benefit realization\nImprovement governance\nPSR closure, action-plan effectiveness, project milestone delivery, sustained savings\nCandidate Profile\nBasic qualifications\nBachelor’s degree in industrial engineering, Manufacturing Engineering, Mechanical Engineering, or a related discipline.\n7-10 years of experience in manufacturing operations, industrial engineering, Lean/continuous improvement, or operational excellence.\nProven experience leading Lean manufacturing initiatives, Kaizen events, Value Stream Mapping, standard-work development, and structured problem solving.\nHands-on shop-floor experience in heavy engineering, turbine manufacturing, power-generation equipment, capital-goods manufacturing, or a comparable heavy-machining environment.\nExperience analyzing complex manufacturing data and translating findings into practical improvement actions.\nStrong working knowledge of MS Excel, PowerPoint, and manufacturing-performance reporting; familiarity with ERP systems is desirable.\nAbility to work independently, manage multiple projects, and influence cross-functional teams.\nPreferred qualifications\nLean Six Sigma Green Belt or Black Belt certification.\nExperience with turbine, generator, rotating equipment, heavy fabrication, machining, or large-assembly manufacturing.\nExposure to stator bar manufacturing, generator stator stacking, winding, insulation, impregnation, or generator assembly.\nExperience in automation feasibility, robotic welding, machine-tending automation, material handling, or Industry 4.0 pilots.\nKnowledge of TPM, OEE improvement, SMED, layout optimization, simulation tools, and capital-project justification.\nExperience supporting new-product industrialization, factory readiness, or shop-floor digitalization.\nCore competencies\nStrong mechanical aptitude and ability to understand complex machining, welding, and assembly processes.\nAnalytical and structured problem-solving capability.\nPractical, hands-on leadership style with credibility on the shop floor.\nClear communication, presentation, facilitation, and stakeholder-management skills.\nAbility to motivate teams and drive behavioral changes in a Lean environment.\nStrong planning, prioritization, and multi-project management skills.\nCommitment to safety, quality standards, and disciplined execution.\nWhat success looks like\nWithin the first 12 months, the successful candidate will have established a visible Operational Excellence operating rhythm, delivered measurable improvements in safety, quality, delivery, OEE, productivity, and lead time, and built capability across production and support teams to sustain results. The role should create a practical improvement pipeline focused on high-impact areas such as heavy machining utilization, welding and fabrication flow, turbine assembly, generator stator manufacturing, material handling, and selective automation. Operational Excellence leaders are commonly expected to align improvement projects with plant leadership, quantify benefits, manage implementation, train teams, and measure sustained results\nJoin us and work with global teams to support global customers ! 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