Freelance Head – Cost Optimization & Operational Excellence

Our client, a global manufacturing & supply chain solutions company is looking to engage with a Head Cost Optimization & Operational Excellence with 15 plus years of experience in Steel fabrication / heavy engineering / structural steel / EPC fabrication shops OR manufacturing consulting (operations / lean / cost transformation) with plant immersion.

Key Responsibilities;

1. Scrap Reduction-

Diagnose scrap across cutting, nesting, welding, rework, and handling

Identify root causes and redesign SOPs and process controls

Implement yield dashboards and lead Kaizen/Six Sigma initiatives

Build plant capability to sustain scrap levels below 4%

2. Throughput & Cycle Time Improvement (Wardha)-

Map end-to-end value stream and identify bottlenecks

Improve line balancing, sequencing, and scheduling discipline

Drive OEE, reduce WIP, idle time, and internal material movement

Unlock incremental capacity without additional capex

3. Freight & Logistics Optimization-

Analyze freight spend by route, mode, and load factor

Optimize dispatch planning, truck utilization, and packaging

Reduce damage-related rework and address commercial leakages

Drive structural reduction in freight cost per ton

NOTE;

Duration - 6 months (Extendable)

Location - Plants at Wardha (40-50% time), Bhilai, Vizag and HO (Bangalore)

Capacity - Full Time and Onsite

Skills Required

• Strong understanding of fabrication and manufacturing processes (cutting, nesting, welding, assembly, rework)
• Expertise in cost optimization, scrap reduction, and yield improvement
• Hands-on experience with Lean Manufacturing, Kaizen, and Six Sigma tools
• Proficiency in Value Stream Mapping (VSM), line balancing, and cycle time reduction
• Ability to analyze shopfloor data and drive root-causebased improvements
• Knowledge of OEE, capacity utilization, and throughput improvement without capex
• Exposure to industrial logistics, freight optimization, and dispatch planning
• Strong stakeholder management across plant, procurement, logistics, and finance teams
• Execution-focused mindset with ability to work on the shopfloor, not just in reports
• Commercial acumen with clear understanding of cost-per-ton and margin levers.