Job Description
Illuminate USA is seeking a results-driven Continuous Improvement / Lean Manager to lead and accelerate factory-wide improvement initiatives across Safety, Quality, Delivery, Cost, and Productivity. This leader will drive structured problem solving, standard work deployment, Kaizen execution, and Lean culture development across the manufacturing organization. This role requires strong facilitation skills, data-driven decision making, and the ability to influence across functions including Production, Equipment Engineering, Maintenance, Process Engineering, Quality, Supply Chain, and EHS.
Key Responsibilities- Lead plant-level Lean transformation efforts including waste elimination, flow improvement, and productivity improvements.
- Drive deployment and maturity of Lean tools:
5S, Standard Work, Visual Management, A3, Kaizen, Value Stream Mapping (VSM), SMED, TPM, and Daily Management Systems (DMS).
- Own the CI roadmap including priorities, timeline, resource alignment, and measurable business outcomes.
- Facilitate and lead Kaizen events, rapid improvement workshops, and cross-functional problem-solving sessions.
- Coach teams on structured root cause methods including 5-Why, Fishbone, 8D, Pareto, and FMEA alignment.
- Ensure countermeasures are implemented sustainably (verified effectiveness, control plan ownership, audit cadence).
- Partner with leadership to establish and drive performance improvement in:
OEE / Availability, Yield, Throughput, Scrap PPM, Cycle Time, Labor Efficiency, Downtime Reduction
- Build and maintain weekly/monthly reporting and review cadence including action tracking, escalations, and closure discipline.
- Support tiered meeting structure and daily accountability routines to improve execution consistency.
- Lead creation and deployment of standardized processes across shifts and workstations.
- Audit and sustain improvements through layered process audits (LPA), leader standard work, and sustainment plans.
- Train, coach, and develop leaders and frontline teams to build CI capability and ownership.
- Lead CI initiatives tied to equipment reliability, line balancing, changeover reduction, material flow, and defect containment.
- Partner with Engineering and Maintenance to improve uptime through TPM elements and defect prevention.
- Support new line ramp, retrofits, and operational readiness activities by ensuring Lean principles are embedded.
Required Qualifications - Bachelor's degree in Engineering, Business, Operations, Industrial Engineering, or related field (or equivalent experience)
- 7+ years of experience in Manufacturing, Operations, or Continuous Improvement roles
- Demonstrated success driving measurable improvements in a high-volume manufacturing environment
- Strong working knowledge of Lean / CI methods and structured problem-solving
- Proven ability to lead cross-functional teams without direct authority
Preferred Qualifications - Lean certification (Lean Six Sigma Green Belt/Black Belt preferred)
- Experience in advanced manufacturing (automation-heavy, high-mix or high-volume preferred)
- Experience implementing Daily Management Systems (DMS) and tiered accountability
- Background in KPI systems (OEE, yield, throughput, cost tracking, scrap reduction)
Physical Requirements - Ability to sit or stand for extended periods of time
- Occasional walking within office and manufacturing areas
- Ability to lift up to 25 lbs on an occasional basis
- Ability to view screens, read documents, and communicate effectively
