Continuous Improvement (CI) Lead

Job Description

Job Description

The Plant CI Leader is primarily responsible for identifying, analyzing, and reducing waste, implementing process improvements, and optimizing operations to enhance efficiency. They also lead continuous improvement practices and foster a culture and mindset focused on continuous improvement initiatives.

Objectives:

• Lead and drive the ideation and execution of productivity initiatives while building a culture of continuous improvement (CI) across the plant.
• Process Improvements: Conduct time studies, process mapping, and workflow analysis to identify bottlenecks and inefficiencies.
• Data Collection: Gather production data to evaluate performance, identify trends, and support improvement projects.
• Data Analysis: Use statistical tools and problem-solving techniques, such as Pareto analysis, SPC, and DOE, to drive data-based decisions
• Lean Manufacturing: Apply Lean principles such as 5S, Kaizen, Standard Work, and SMED to improve processes
• Six Sigma: Support Six Sigma projects aimed at reducing defects, improving quality, and minimizing process variation.
• Support Production: Work with operators and supervisors to implement standardized work procedures and best practices.
• Issue Resolution: Assist in troubleshooting process issues and recommend solutions to improve efficiency and product quality.
• Standardization: Develop and update standard operating procedures (SOPs) to ensure sustainability of improvements.
• Documentation: Maintain records of process changes, improvement projects, and cost savings achieved.
• CI Support: Support training initiatives to help employees understand and apply CI tools and techniques.
• Engage employees in kaizen / workshops to analyze processes and implement/standardize sustainable solutions.
• Train employees on CI tools (process flow, kaizen, six sigma, plan-do-check-act (PDCA) cycle)
• Lead in organizing access/training to plant users on WAVE as one source of tool to map ideation (L1).
• Drive the execution schedule and cadence with the general manager for evaluating and implementing improvements and manage the productivity performance of the plant
• Collaborate and Develop roadmap with Plant Leadership team for the plant to achieve manufacturing Best in Class (Silver/Gold) standard
• Evaluate new and existing processes, equipment, and materials as an input for scheduling methods, performance metrics, and financial standards

Behavioral Expectations:

• Safety-First: A safety-first mindset is a proactive approach to safety, where all employees keep an eye out for safety issues and avoid potentially dangerous situations which could likely cause danger, risk, or injury. This also means that everyone has responsibility for safety regardless of role, level, title, or job.
• Continuous Improvement: Always looking for ways we can improve and standardize our work even when everything is going well. By doing so, it will drive consistent progress toward improved business performance and will tap into people's desire to be the best at what they do.
• Compliant: Employee compliance is achieved when workers are familiar with all the laws that govern their industry or job and know how to conduct business in an ethical manner. It often requires procedural training and encouragement to learn from mistakes.
• Driving Results: Identify specific purpose, goal, or destination and prioritize making progress toward it. Focus discussions on what you want to achieve and why. Everyone knows their role and is accountable for driving their work to achieve a common goal.
• ONE Team: One team means being part of a group that shares strong relationships, trust, respect, and a common vision for what "good" looks like. One team means supporting and relying on one another to achieve and drive business priorities and meet customer commitments.

Job Qualifications:

• Education: Bachelor's degree (or equivalent) in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or a related field. Lean Six Sigma Green Belt certification is beneficial.
• Minimum 3-5 years experience in process improvement, manufacturing engineering, or a related field in an automotive or high-volume manufacturing environment.
• Demonstrated experience in applying Lean Manufacturing, Six Sigma, and other CI Methodologies in a production setting.
• Knowledge of Lean tools such as 5S, Kaizen, Standard Work, Line balancing, SMED, OEE and Value Stream Mapping.
• Strong data analysis skills with proficiency in Excel, Minitab, or other statistical software.
• Familiarity with manufacturing execution systems (MES), ERP software, and production tracking tools.
• Understanding of automotive standards (IATF 16949, ISO 9001) and quality control principles.
• CAD software proficiency (AutoCAD, SolidWorks) is a plus for process layout optimization.
• Strong problem-solving abilities with a hands-on approach to troubleshooting process inefficiencies.
• Willingness to travel to manufacturing sites as needed.