Continuous Improvement Specialist

The Continuous Improvement Manager is responsible for driving operational excellence through the identification, analysis, and implementation of process improvements. This role focuses on enhancing efficiency, reducing costs, and improving process and product quality by using the principles and methodologies of Lean, Continuous Improvement, and to a lesser extent, Six Sigma methodologies, as detailed below. The CI Manager will lead cross-functional teams to ensure that improvement initiatives align with organizational goals and are effectively integrated into daily operations.

Major Functions:

1. Safety and Risk Management
2. Lead by example to promote a safety-first culture across all projects and activities.
3. Ensure all safety protocols are followed during process improvement initiatives.
4. Identify and mitigate potential safety risks associated with process changes.

1. Process Analysis and Improvement
2. Lead cross-functional teams that will gather information to evaluate current work processes and identify improvement strategies. Facilitate employee team meetings to build cohesiveness and improve project team results.
3. Conduct thorough analysis of current manufacturing and business processes to identify inefficiencies, bottlenecks, and areas for improvement through the use of Value Stream Mapping and other tools.
4. Deploy Lean methodologies to develop and implement process improvements that reduce waste, enhance efficiency, and improve product quality, especially in the areas of scrap reduction, cycle and lead time analyses, cost implications of poor processes, visual management, and SQDP metric improvement. Tools might include: Kanban, Yamazumis, SMED, TPM, Single Piece Flow, 5S, Work Cell Optimization
5. Conduct Root Cause Analysis as needed and coach others as necessary
6. Collaborate with all functions to implement continuous process improvement.
7. Establish sustainable controls and processes, monitor and evaluate the effectiveness of implemented improvements, and make adjustments as necessary.
8. Deploy, maintain and help to improve the efficacy of standard Visual Management Systems, Tier Board Meetings, Kamishibai process audit systems, Leader Standard Work, etc.

1. Deployment of Six Sigma Processes to Improve Product/Process Design, along with other CI personnel, including:
2. Design of Experiments
3. Process Capability (Cpk, Ppk) and Statistical Process Control (SPC)
4. Design for Manufacturability/Assembly
5. DFMEA, PFMEA, MSA and other PPAP type requirements

1. Data Collection and Analysis
2. Collect and analyze data related to production processes, equipment performance, and product quality.
3. Utilize statistical tools to identify trends, correlations, and root causes of process inefficiencies.
4. Prepare detailed reports and presentations that communicate findings, proposed solutions, and projected outcomes of improvement initiatives.

1. Project Management
2. Lead and manage continuous improvement projects from conception through implementation, ensuring projects are completed on time and within budget.
3. Develop project plans, including timelines, resource allocation, and risk management strategies.
4. Coordinate with cross-functional teams to ensure all stakeholders are aligned and engaged throughout the project lifecycle.
5. Training and Development
6. Train and coach employees on all levels of continuous improvement methodologies, tools, and techniques.
7. Facilitate workshops and training sessions to build organizational capability in Lean, Six Sigma, and other process improvement approaches.
8. Foster a culture of continuous improvement by encouraging employee participation in process improvement initiatives.

1. Continuous Improvement Strategy
2. Lead the development and execution of the company’s continuous improvement strategy.
3. Identify and prioritize improvement opportunities that align with the company’s strategic objectives.
4. Lead in the pursuit of operational excellence and cost reduction.

Accountability of Employees:

• Utilize full capability to achieve assigned outputs and drive continuous improvement.
• Inform the manager promptly when circumstances prevent achieving outputs or when further improvements can be made.
• Actively contribute ideas and participate in decision-making processes related to process improvements.
• Seek guidance from the manager when needed to ensure optimal performance and outcomes.

Minimum Qualifications:

• Bachelor’s Degree in Engineering, Business, Systems, or Continuous Improvement
• Lean Six Sigma Green Belt, or equivalent, from a reputable organization along with sound, demonstrable knowledge and experience.
• Strong problem-solving skills.
• Extensive experience in teaching and coaching
• Dynamic presentation/coaching skills
• At least 5 years of proven experience in the Lean Six Sigma world
• Manufacturing and office processes experience
• Process Design experience is a plus
• DOE and process capability knowledge and experience is a plus
• Experience in project management and leading cross-functional teams.
• Some level of proficiency in data analysis and statistical tools (e.g., Minitab, Excel).