Continuous Improvement Manager - Ply Gem Windows at Cornerstone Building Brands, Inc. in West Sacramento, CA

Responsibilities

LEAD SITE GUIDING COALITION

• Be the change agent – drive and accelerate change in culture, attitude, and capability
• Annual planning of RIE activities to support Site Strategy Deployment based on Value Stream Mapping, Should Cost, and/or Waste Analysis
• Quarterly priority setting of RIEs to deliver step change in results (60 – 90 day outlook) at the target pace for the site
• Approval of RIE 30-day close-out and sustainment plans
• Ensure Lean tool capability is developed across the site
• Drive employee engagement by ensuring a high percentage of new members on RIEs
• Approval of standards, systems, and processes to support sustainable execution
• Approval of site standards as related to Lean methodologies and implementation
• Develop, modify, and improve standard processes to continuously improve efficiency of Coalition related to the above responsibilities
• Instill a standard, disciplined, rigorous, process focused approach to problem solving across the organization
• Actively participate in the Windows Lean Council to share, develop, and deploy Division standards for Lean tools, principles, and methodologies as well as standard business processes

DAILY / ACTIVE WASTE ELIMINATION COACHING

• Facilitate daily / weekly Production Department walk throughs with Operations Manager or Production Managers to highlight opportunities for continuous improvement in Lean principles / tools and adherence to site standards
• Participate in weekly (or periodic based on site) Production Department meetings to support development of corrective actions and coach problem solving methodology
• Participate in periodic Functional Department meetings to identify gaps / issues which need resolution, assist in the prioritization of work processes, and support in the development of corrective actions
• Outside of the Production Departments or Functional Department meetings (monthly minimum), coach structure and linkage of the Business Boards to ensure proper cascade of measures, targets, and actions from Leadership to shop floor
• Identify and lead training in accordance with the needs defined by the Guiding Coalition, Site Strategy Deployment, and personal observation (daily coaching and walk throughs). Ensure proper understanding of these tools / techniques and ownership of deployment.

RIE FACILITATION

• Drive the site to model a Learn By Doing approach (Dirty Hands University)
• Organize / facilitate RIE-based and specific tool training for all monthly RIE teams
• Coordinate Preparation, Execution, and Follow-Up stages of the RIE process through weekly interaction with Leaders / Co-Leaders to ensure team is on pace with the guidelines / expectations per both the Charter and RIE Guides.
• For RIE teams that go beyond the desired 30-day close-out window, work with Team Leaders / Co-Leaders and Business Owner to close all open follow-up items and execute countermeasures to close gaps against desired deliverables / results

LEAN TOOL CAPABILITY

• Develop personal mastery in the Lean principles and tools to allow broad facilitation (RIE, lean workshops, and daily coaching) in Production Departments and Functions. This shall include a mastery of training modules such as Waste Elimination, 5S, Root Cause Problem Solving, Standard Work, SMED, AM/PM, Plan-Do-Check-Act, and DMS at a minimum.
• Coordinate the Lean Apprentice process to ensure the site has broad base capability in all primary Lean tools to be self-sufficient for monthly and on-demand training requirements
• Lead training sessions and RIEs within the site or within other Ply Gem facilities as required
• Hold the Guiding Coalition accountable to the Learn, Do, Teach Model

REAPPLICATION / BENCHMARKING

• Develop and facilitate reapplication matrix / process within the site the ensure best practices are shared and reapplied efficiently to accelerate results
• Actively participate in the Windows Lean Council – share successful improvements with the network for potential reapplication to accelerate Company results and be open to learning from other site to reapply successful, sustained improvements
• Actively participate in Benchmarking visits and audits as required at Ply Gem Windows sites. The expected output from any such visit is a potential list of potential reapplications to be reviewed and inserted into the Site Reapplication Matrix as aligned by respective Business Owner
• Identify industries / companies / sites within the same geographic region to conduct external benchmarking based on performance and Lean journey progress

STRATEGY DEPLOYMENT

• Provide support to Lean Council sub-teams (i.e. OEE, AM, PM) in their implementation of actions, sharing his knowledge and practical experience in handling lean tools as required
• Ensure process confirmation through a relevant Go-Look-See process, to understand, support / coach, and challenge associates toward the achievement of expected business results
• In conjunction with the Plant Manager, lead the Site Leadership Team in the development of the Site Roadmap linked to the Company Strategies and Objectives
• In conjunction with the Plant Manager, lead / coordinate the Site Leadership Team in development of annual Strategy Deployment X-Matrix, Scorecard, and Action Plans to achieve the Company annual plan
• Coordinate the monthly Strategy Deployment process including normal updates, gap analysis, and countermeasure development
• Conduct periodic reviews of the Site, Production Department, and Functional Department Business Boards to ensure ongoing alignment to the annual objectives, linked KPIs, site initiatives, and site standards
• Manage the preparation of daily reports.

Education

• BA / BS (4-year technical or business) degree preferable

Experience

• 4 – 6 years of Manufacturing Operations experience
• Previous Lean experience a positive for internal candidates and required for external candidates; High school graduate with some college.

Skills/Abilities

• Able to build successful teams and guide others in accomplishing work objectives
• Strong analytical and problem solving capabilities
• Seeks and uses ‘customer’ feedback to improve effectiveness of Lean group and deployment
• Encourages open discussion and dialogue within and between Functions
• Well developed decision making skills
• Excellent computer and analytical skills
• Excellent verbal, written and interpersonal communication skills
• Lead and Manage by Influence
• Individual and Team Coaching
• Extremely Process Focused
• Excellent self-motivation and attitude toward their work
• High degree of maturity and professionalism