17th July, 2021
Description of Project:
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USAID has awarded Cardno a five-year contract to promote resilient, self-sustaining market systems, and to facilitate the private sector’s improved competitiveness in local, regional, and global markets. Through USAID Compete Activity, Cardno works to empower firms, organizations, and institutions to improve market systems. USAID Compete focuses on three key export-oriented sectors (Information and Communications Technologies (ICT), wood processing, and food processing) to sustainably increase their competitiveness. By working to address constraints across the system, USAID Compete will enable scalable and systemic change to occur, stimulating job creation and increased private sector ability to engage in local, regional, and international markets. The expected results of USAID Compete across all three sectors are: 1) market systems are strengthened to increase sector competitiveness and 2) market actors within those market systems are more productive and competitive.
Name of Position: Lean Manufacturing Specialist
USAID Compete Activity seeks to promote best practices in lean manufacturing for a select number of companies in the food processing sector who can serve as champions for the rest of the industry through follow-up peer learning activities. The Lean Manufacturing Specialist (“Consultant”) will support select food processing companies in Kosovo (chosen through close consultations with sector associations) to adopt lean manufacturing practices to improve process optimization.
It is now widely recognized that “lean manufacturing” techniques can induce significant improvements in companies that apply this methodology. Applying such best practice techniques encompassed within a “lean environment” will help participating companies to become more effective and improve overall productivity. Such improvements are also inherently linked with improved export performance.
The overall goal of the assignment is to provide practical, hand-on support and advice among the selected beneficiary companies through structured training and a coaching program.
The Consultant is expected to deliver a program that includes capacity building support and an in-plant implementation activity, as follows:
1. Capacity building program through mentorship:
a. The proposed project objectives are to improve overall performance of the participating enterprises through coaching on best practice manufacturing techniques based on “Lean Principles.”
b. The target group will be up to three companies with selected staff (management and employees) who want to improve their competitiveness and gain a greater understanding of the benefits lean manufacturing can provide to their companies.
2. In-plant implementation of lean manufacturing:
a. A lean manufacturing intervention will be implemented in three companies from the food sector, to be selected based on consultations with sector associations. Company selection will also depend on their willingness to cost-share the interventions and engage in peer-learning exchanges after the fact to disseminate knowledge and practices.
Specific Tasks and Responsibilities
The objective of the Lean Manufacturing Program is to increase the knowledge and capability of the targeted companies’ management and staff to adopt a systematic approach to good manufacturing practices encompassing lean techniques at the enterprise level.
1. The Lean Manufacturing capacity building program, will entail at least the following topics:
o 5S methodology
o Waste Reduction
o Development of cross-functional lean teams
o Value stream mapping
o Changes in workshop layout
o Streamlining material/inventory and information flow
o Total Productive Maintenance (TPM)
o Kanban and one-piece flow
o Process stabilization and various tools of productivity improvement.
2. The in-plant implementation activity at the company level will include:
a. Establishment of an internal Lean Improvement Team (LIT) which will be responsible for the implementation and dissemination of knowledge and techniques to the wider workforce.
b. Visit the participating company and evaluate its current production systems along with all processes and operations to understand the gaps in best practice and specifically look for inefficiencies, bottlenecks, quality issues, and waste problems. Establish, agree, and document an action plan for implementation of the below techniques with each enterprise and their team members.
c. The Consultant will work with the LIT to coach and assist with implementing the foundation of Lean Process Improvement by undertaking the following:
i. Review with the LIT the potential for waste reduction (Muda: “Learning to See, Identify and eliminate the 7 wastes”)
ii. With the LIT develop a general Value Stream Map to highlight wastes and non-value time
iii. With the LIT implement the 5S methodology:
1. Seiri (Sort)
2. Seiton (Set in Order)
3. Seiso (Shine)
4. Seiketsu (Standardise)
5. Shitsuke (Sustain)
d. Poka Yoke (mistake proofing techniques and defect reduction)
e. Approach to One Piece Flow and Kanban (Lean Flow and Pull Systems)
f. Cell Layout advantages and Team Working
g. Standardised Work
h. Kaizen and continuous improvement
i. Develop LIT action Plans with KPIs.
The Consultant will work closely with USAID Compete team and sector associations in the selection of the pilot companies. Such selection will be done objectively and a key criterion will include willingness of companies to provide cost-share.
Minimum Education Requirement
Relevant University Degree
Minimum Professional Experience
· Minimum 5 years of relevant experience implementing similar activities.
· Experience on supporting lean improvement in private sector clients, including in the region, is considered a distinct advantage.
· Demonstrated ability to interact with private sector companies.
· Strong interpersonal skills and exceptional ability to motivate teams.
· Strong written skills in English.
Period of Performance
August 2021 - November 2021
Level of Effort
Up to 50 working days. Remuneration will be conducted based on monthly submission of timesheets and activity log for the activities undertaken.
The Consultant will be required to provide regular reporting on the implementation of the activities and achievement of milestones.
USAID Compete Activity’s Food Processing Sector Lead and Business Sophistication Expert.
To apply please submit your CV and a one-page cover letter in English.
Please send the requested documents electronically to the following email: firstname.lastname@example.org
All submissions must be received on or before July 28, 2021. Only shortlisted candidates will be interviewed.