Job Title: Head TPM
Location: Bangalore (HO)
Objective of the role:
Lead the Total Productive Management (TPM) operations at UBL to minimize avoidable financial losses in manufacturing by developing and reviewing plans/programs, training and up-skilling brewery talent and implementing process improvements defined within the TPM methodology; Support change management programs and audits conducted at the Brewery.
Key Accountabilities:
TPM Planning and Assessment
- Contribute to development of year-long TPM plan for each pillar, across all the activities, at the brewery; Share with Head TPM at HO and finalize year-long plan incorporating feedback received.
- Based on audit findings from Heineken representatives, determine progression plans and projects for improvement on TPM indices across pillars.
- Design competitions for each quarter at the brewery for operators/workmen and managerial employees.
- Identify improvement opportunities based on assessment of quarterly deployments and lead the design of requite intervention project(s).
- Prepare TPM department presentations and analysis reports to share with relevant stakeholders, at the plant and at HO, as required.
- Develop the TPM expense budget for UBL and share with relevant stakeholders for feedback and approval.
TPM Implementation
- Coach and lead TPM pillar members and projects members to understand TPM routes for various losses and issues.
- Conduct demonstrations of TPM routes to help brewery teams better understand the TPM methodology.
- Support stepwise progression as per pillar route e.g. preventive maintenance plan development with PM Pillar.
- Conduct monthly reviews with Pillar teams, prepare plan to assess progress on master-plan and share feedback with relevant stakeholders.
- Co-ordinate weekly Pillar Meetings and weekly TPM Leadership team meetings; review pillar progress & facilitate Leadership team support to overcome cross functional/pillar issues.
- Support preparation of quarterly/ monthly deployments of Priority 1 KPIs; Support pillars for preparing DS of Priority-1 KPIs & identification of improvement projects.
- Support preparation of MRM presentations and ensure all TPM data is updated on the system
- Facilitate planning & implementation of change management activities by launching campaigns, driving employee participation.
- Support activities like simplifying formats, converting to vernacular languages and sharing best practices to enable horizontal deployment of initiatives/learnings.
TPM Training
- Lead conduct of trainings on the TPM methodology and the various concepts involved for various pillars, project teams and new joiners.
- Lead preparation of Monthly TPM training calendar & follow-up with internal trainers for seamless execution.
- Drive completion and assessment of pre-training and post-training feedback questionnaire to measure training effectiveness.
- Guide and develop Internal Trainers at the Brewery to aid in effective training implementation.
TPM Audit
- Lead audits on shopfloor along with Pillar leaders to track Pillar progression and develop requisite plans for optimization.
- Conduct sustenance audits for completed projects, identify gaps and submit reports to relevant stakeholders.
- Train and develop internal audit team at the brewery and provide technical guidance during audits.
- Participate & support brewery teams during conduct of external audits like FSMS, External Electrical Audits, PASS Audits etc.
- Facilitate Gemba walk for relevant stakeholders.
Job Challenges
- Coordinating with a wide range of stakeholders across various pillars of TPM at the Brewery.
- Creating a new culture focused on TPM requires time and willingness from shop-floor employees.
Education and Experience Guidelines
- Minimum qualification: B.E.
- TPM/Six Sigma Certifications (good to have)
- Minimum 10-12 years with experience in a large manufacturing organization
- Specific experience in TPM implementation and plant operations
- Knowledge of continuous improvement in manufacturing
