Continuous Improvement Lead

Continuous Improvement and P-30 Leader

At Aalberts integrated piping systems Americas, Inc., we have the best, most complete flow control device and connection technology portfolio in the industry. Our goal is to make it an easier and better buying experience by being the only organization that offers a complete line of flow control devices and piping systems solutions. We feature a full range of connections, including push, press, thread, groove, sweat, and crimp to fit your Commercial, Industrial, and Backflow Prevention needs. At Aalberts IPSA, we recognize the importance of providing our employees with a good work environment and an excellent benefits package.

Summary: The continuous improvement & P-30 leader serves as a champion for successful and sustained lean implementation, in the region or division. This position requires a leader who is in charge to manage the regional or business group CI network, to improve the manufacturing efficiency of the sites (safety, scrap, delivery, direct labor productivity, OEE, and other cost), deploy the group CI and business group operation strategies & initiatives and to support site team in continuous improvement activities. In additional, the continuous improvement - P-30 leader, will ensure to follow up of all the productivity projects at business group in the areas: material (technical & resourcing) actions and raw material consumption out of index - make or buy projects.

Essential Duties and Responsibilities:

Lean Network Competences

• Work closely with regional COO or business group COO to build the CI network according to the operation strategy.
• Support the Plant / Site Managers, APU Managers and Plant / Site CI Managers to understand the CI strategies and apply the Lean tools.
• Support the production supervisors to understand the importance of the respect of the standards and their improvement role.
• Ensure that Plant / Site CI Managers network is permanently fulfilled at right level for success.
• Manage the Plant / Site CI Managers network of the region or division: annual professional competences appraisal, contribution & validation to recruitment, definition of training plan, validation of lean skill development and manage detection/growing of local production system potentials. Organize network meeting and On Job Training.
• Organize the cross fertilization of good practices within the region or division.

Lean Strategies

• Ensure that lean rules are taken into account in new projects at right time.
• Validate the Sites lean deployment plan vs Group directives & instructions, and Sites Priorities, including Smart factory/Industrial 4.0, and support their deployment.
• Help the Plant / Site Managers identify opportunities for SQDICP progress.
• Deploy and follow Group initiatives within his/her region or division.
• Check through a regular presence on every Site of his region or division that Sites are working on appropriate priorities.

Lean GEMBA Activities

• Coach Plant / Site Managers: Plant, Production, APU, CI, Production & Supply Chain support functions on lean processes implementation.
• Check regularly Gemba in depth the proper deployment of lean roadmaps and ensure a close follow up of progress plans.

Lean Results

• Challenge the plants’ budget & related financial indicators of sites in budget preparation phase.
• Validate, challenge & follow Direct Labor and equipment operational performance improvement actions and lean reporting.

Lean Standard Development Contribution

• Contribute to the improvement of Group Lean standards & tools.
• Support industrial 4.0 / smart factory implementation.
• As Aalberts Production System roadmap developer.
• Participate to Group Kaizen workshops, Committees & townhall.
• Contribute to selected Group initiatives upon request.

Site Support

• Troubleshooting and help building progress roadmaps for sites when in crisis.

P-30 Strategies & Activities

• Review key productivities at business group and level support teams to define the best implementation strategy.
• Review key productivities at business group level to assess applicability of ideas transversally at other sites in order to coordinate validation and globalize project efforts.
• Ensure sites are managing payback of any productivity project being managed.
• Support workshops in the sites and at suppliers to improve savings portfolio.
• Continuously monitor TOP 10 productivities in the sites.
• Prepare & organize monthly productivity review meetings.
• Support teams to remove roadblocks on key projects to meet productivity project milestones.
• Benchmark products and best internal / external industrial practices and deploy to all sites.
• Coach and guide the project managers to organize cost improvement workshops.

Qualification/Requirements:

• Bachelor’s or master’s degree in engineering or a related field.
• Extensive hands-on experience (>10 years) in Lean methodologies, such as Lean Six Sigma, Kaizen, Muda hunting, Standard Work, Cycle time balance with automation design, SMED, TPM, Value Stream Mapping, and Lean product line design, plant layout and logistic warehouse layout optimization, Design for 6 Sigma.
• Extensive hands-on experience in developing smart factory/industrial 4.0 (MES, E-KANBAN, AGV/ARM).
• Extensive hands-on experience on developing or improving lean training, tools and methods.
• Strong project management skills, with the ability to manage multiple projects simultaneously and meet deadlines.
• Excellent analytical and problem-solving abilities, with a data-driven approach to decision-making.
• Exceptional leadership and communication skills, with the ability to inspire and influence operation teams at all levels.
• Change management expertise, with the ability to manage resistance and drive cultural transformation.
• Proficiency in using Lean software tools and technologies for process mapping, data analysis, and reporting (PPT, Excel, AutoCAD).
• Strong international mindset and a good ability to interact with all levels of the organization. Be able to lead and continuously motivate teams to push and achieve savings.

Desired Qualifications:

• Bachelor’s degree in Mechanical or Industrial Engineering.
• 8 years of Lean manufacturing within the automotive industry.
• Strong background experience in purchasing, program management, manufacturing and /or supply chain management.
• American Society for Quality (ASQ) Certified Six Sigma Black Belt (CSSBB) preferred.