Job Description

General Description:

The Continuous Improvement Director 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 product quality by using engineering principles and various Lean and Six Sigma methodologies as detailed below. The engineer will lead with cross-functional teams to ensure that improvement initiatives align with organizational goals and are effectively integrated into daily operations.

Major Functions:

Safety and Risk Management

• Lead by example to promote a safety-first culture across all projects and activities.
• Ensure all safety protocols are followed during process improvement initiatives.
• Identify and mitigate potential safety risks associated with process changes.

Process Analysis and Improvement

• 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.
• Conduct thorough analysis of current manufacturing and business processes to identify inefficiencies, bottlenecks, and areas for improvement.
• 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 usage might include: Kanban, SMED, TPM, Single Piece Flow, 5S, Work Cell Optimization
• Conduct Root Cause Analysis as needed and coach others as necessary
• Collaborate with all functions to implement continuous process improvement.
• Establish sustainable controls and processes, monitor and evaluate the effectiveness of implemented improvements, and make adjustments as necessary.

Deployment of Special Six Sigma Processes to Improve Process Design

• Design of Experiments
• Process Capability (Cpk, Ppk)
• Statistical Process Control
• Design for Manufacturability/Assembly
• Value Analysis/Value Engineering
• DFMEA and PFMEA and other PPAP type requirements
• Train, mentor and coach manufacturing, design, and quality engineers along with production leadership on the above methodologies

Data Collection and Analysis

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

Project Management

• Lead and manage continuous improvement projects from conception through implementation, ensuring projects are completed on time and within budget.
• Develop project plans, including timelines, resource allocation, and risk management strategies.
• Coordinate with cross-functional teams to ensure all stakeholders are aligned and engaged throughout the project lifecycle.

Training and Development

• Train and coach employees on all levels of continuous improvement methodologies, tools, and techniques.
• Facilitate workshops and training sessions to build organizational capability in Lean, Six Sigma, and other process improvement approaches.
• Foster a culture of continuous improvement by encouraging employee participation in process improvement initiatives.

Continuous Improvement Strategy

• Lead the development and execution of the company’s continuous improvement strategy.
• Identify and prioritize improvement opportunities that align with the company’s strategic objectives.
• Lead in the pursuit of operational excellence and cost reduction.

Minimum Qualifications:

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

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