Director of Lean and Continuous Improvement

Power Solutions International (PSI) is a leader in large gen-set packaging and enclosures. We provide turnkey, custom power packages that integrate alternators, cooling systems, controls, switchgear, cabling, and protection, delivered as containerized, skid, or walk-in solutions. Our team manages the full lifecycle from application engineering and 3D design to structural fabrication, wiring and piping, sound and thermal management, code compliance, factory acceptance testing, and site support. With scalable production capacity and disciplined program management, PSI delivers repeatable quality and reliable performance on complex builds for mission-critical and industrial applications worldwide.

Position Summary:

The Director of Lean and Continuous Improvement is responsible for leading the organization’s efforts to achieve operational excellence, efficiency, and cultural transformation. This role oversees the development and execution of the company’s Lean, Six Sigma, and continuous improvement strategy while managing key operational support functions — including Safety, Facilities, Industrial Engineering, and Project Management.

The Director will be instrumental in embedding a continuous improvement mindset across all business units, driving productivity gains, cost reduction, and quality enhancement, while ensuring a safe, efficient, and sustainable workplace. This position will be based in Darien, WI and travel to Beloit, WI as needed.

Key Responsibilities:

Strategic Leadership

• Develop and implement the organization’s Lean and Continuous Improvement roadmap aligned with corporate strategy
• Direct and integrate the functions of Safety, Facilities, Industrial Engineering, and Project Management, ensuring cross-functional alignment with operational goals
• Serve as a strategic partner to leadership, influencing long-term manufacturing and process optimization initiatives
• Lead the adoption of digital automation, data analytics, and AI-enabled tools that enhance process performance and decision-making

Operational Excellence

• Champion Lean methodologies (Kaizen, 5S, Value Stream Mapping, SMED, Kanban, etc.) to eliminate waste and improve throughput
• Oversee Industrial Engineering efforts to optimize layouts, material flow, and labor utilization
• Collaborate with Safety to maintain a proactive, zero-incident culture and regulatory compliance
• Drive Facilities improvements to support lean layouts, energy efficiency, and equipment reliability
• Manage large-scale capital and improvement projects through the Project Management function, ensuring scope, budget, and timeline adherence

Continuous Improvement & Change Management

• Lead continuous improvement initiatives across manufacturing and business processes, ensuring measurable, sustainable results
• Build a company-wide culture that empowers employees to identify and solve problems at their source
• Develop metrics and reporting systems to monitor the performance of Lean and CI initiatives
• Provide training and coaching in Lean, Six Sigma, and problem-solving tools at all organizational levels

Leadership & Team Development

• Recruit, develop, and lead a high-performing team across Safety, Facilities, Industrial Engineering, and Project Management disciplines
• Foster collaboration and professional growth through mentorship, succession planning, and skills development
• Promote employee engagement and accountability in operational excellence

Education:

• Bachelor’s degree in Engineering, Operations Management, or a related field required
• Master’s degree or MBA preferred

Experience:

• 10 years of progressive experience in manufacturing or operations leadership, including at least 5 years in Lean or Continuous Improvement leadership
• Proven success leading cross-functional teams and delivering measurable operational improvements
• Experience overseeing Safety, Facilities, or Engineering functions strongly preferred
• Familiarity with automation, data-driven manufacturing, and digital transformation initiatives a plus

Preferred Qualifications:

• Lean Six Sigma Black Belt or Master Black Belt certification required (or equivalent experience)
• PMP certification preferred

PSI offers a wide range of benefits from medical, dental, and vision to pet insurance as well as discounted prescription plans. Additionally, we also provide a 401k match, life insurance and AD&D, short- and long-term disability, and an employee assistance program. Come join our team and learn more about PSI and what we have to offer!

Power Solutions International/3Pi is an EOE disability/vet company offering a drug-free workplace. We celebrate diversity and are committed to creating an inclusive environment for all employees.