Continuous Improvement Manager

SUMMARY:

The Continuous Improvement Manager will lead the development and implementation of a Lean Operating System to drive operational excellence at United Alloy, a premier manufacturer of metal fabrication and assembly solutions. Based in Janesville, WI, this role will focus on optimizing production processes, eliminating waste, and fostering a culture of continuous improvement through advanced Lean methodologies. The successful candidate will collaborate with cross-functional teams across United Alloy’s facilities to align initiatives with strategic manufacturing goals, ensuring sustainable performance improvements and operational efficiency.

ESSENTIAL DUTIES & RESPONSIBILITIES:

Lean Operating System Design & Implementation:

• Develop and deploy a standardized Lean Operating System tailored to United Alloy’s metal fabrication and assembly operations.
• Embed Lean principles (e.g., value stream mapping, 5S, Kaizen, Kanban, SMED, Poka-Yoke, Heijunka) as foundational elements of production workflows.
• Create tools, templates, and metrics to sustain Lean practices across United Alloy’s Janesville and other facilities.

Process Optimization:

• Identify inefficiencies, bottlenecks, and waste in manufacturing processes using Lean tools and root cause analysis techniques (e.g., 5 Whys, Fishbone Diagrams, Pareto Analysis).
• Lead value stream mapping initiatives to streamline production flows, reduce lead times, and improve throughput for United Alloy’s custom metal products.
• Implement solutions to enhance product quality, equipment uptime, and shop floor productivity.

Continuous Improvement Leadership:

• Facilitate Kaizen events, Gemba walks, and rapid improvement workshops to drive immediate and long-term gains at United Alloy’s Janesville and other sites.
• Coach manufacturing teams on Lean principles, fostering a proactive problem-solving culture across all United Alloy facilities.
• Develop and deliver training programs on Lean tools, root cause analysis, and continuous improvement methodologies for United Alloy employees.

Performance Measurement:

• Define and monitor manufacturing KPIs (e.g., OEE, cycle time, defect rates) to evaluate the effectiveness of the Lean Operating System at United Alloy.
• Leverage data analytics to uncover trends, perform root cause analysis, and identify improvement opportunities in production processes.
• Report progress and impact to the Director of Lean & Advanced Manufacturing, linking outcomes to United Alloy’s business objectives.

Cross-Functional Collaboration:

• Partner with United Alloy’s production, quality, supply chain, and engineering teams to align Lean initiatives with manufacturing goals across all facilities.
• Drive adoption of Lean practices across shop floors and support functions, acting as a change agent within the Janesville facility and beyond.

Sustainability & Scalability:

• Ensure Lean processes are sustainable and scalable to support United Alloy’s growth and diverse product lines across all manufacturing sites.
• Establish auditing and feedback mechanisms to refine and maintain the Lean Operating System at United Alloy.

QUALIFICATIONS:

• Bachelor’s degree in Industrial Engineering, Manufacturing, Operations Management, or related field.
• 5 years of experience in continuous improvement or Lean implementation within manufacturing environments, preferably in metal fabrication or assembly.
• Proven success in designing and deploying Lean Operating Systems in production settings.
• Certifications such as Lean Six Sigma Black Belt, Kaizen Facilitator, or equivalent required.
• Expertise in Lean tools (e.g., value stream mapping, 5S, SMED, Kanban, Poka-Yoke, Heijunka, Takt Time, Andon) and root cause analysis (e.g., 5 Whys, Fishbone Diagrams, Pareto Analysis).
• Strong analytical skills with proficiency in manufacturing data tools (e.g., Excel, Minitab, ERP systems, Power BI).
• Exceptional leadership, communication, and change management skills to engage United Alloy’s shop floor and leadership teams.
• Ability to influence and drive Lean adoption in a fast-paced manufacturing environment.
• 12 Expected Behaviors of Actively Engaged Person – 100% Responsible, Trustworthy, Team Player, Clear Communicator, Empathy, Humility, Emotional Self-Control, Resolves Conflict Directly, Positive Attitude, Respects Others, Problem Solver, and Agile.

Preferred Skills:

• Experience with metal fabrication, welding, or assembly processes relevant to United Alloy’s operations.
• Knowledge of advanced manufacturing technologies (e.g., automation, IoT, Industry 4.0).
• Familiarity with TPM (Total Productive Maintenance) and OEE optimization.
• Experience with project management methodologies (e.g., Agile, PMP).

Work Environment:

• Full-time role requiring regular presence on the manufacturing shop floor at United Alloy’s Janesville, WI facility.
• Approximately 20% travel to other United Alloy factories to support Lean initiatives and ensure consistency across sites.

Compensation:

• Competitive salary commensurate with experience, plus United Alloy’s comprehensive benefits package.