Lead Manufacturing Process Innovation ConsultantLocation: Auburn Hills, MI (Onsite)
Team: Munro & Associates
Type: Full-time
The OpportunityWe're seeking a
Lead Manufacturing Process Innovation Consultant who blends
industrial design-grade creativity with
manufacturing engineering depth. You'll map current states, imagine better futures, and then make them real-translating sketches and storyboards into station concepts, line designs, fixtures, and standard work that cut cost and complexity without sacrificing quality.
This role tilts toward
process design and
factory-floor problem solving, while keeping a strong thread of
visual storytelling, rapid ideation, and human-centered design.
What You'll Do- Lead high-energy ideation sprints and 3P-style workshops to reimagine cells, lines, and material flow; storyboard concepts that stakeholders can immediately grasp.
- Design practical improvements: line balancing, takt alignment, standard work, mistake-proofing (poka-yoke), ergonomic station layouts, and right-sized automation.
- Visualize fast-whiteboard, sketch, simple 3D/CAD, and mockups to converge quickly on buildable solutions.
- Run diagnostics: time studies, VSM, constraint analysis, and waste identification to target highest-ROI changes.
- Prototype and pilot fixtures, jigs, and work aids; translate concepts into clear specifications and build packages.
- Apply DFMA & lean to simplify assemblies upstream and reduce process variation downstream.
- Quantify the impact with cost models and before/after KPIs (labor, throughput, yield, changeover time, floor space).
- Drive adoption: facilitate operator trials, craft crisp executive readouts, and guide phased implementation.
What You'll Bring- 6-12+ years in manufacturing/industrial engineering or advanced operations consulting, with a portfolio of process redesign and cost-down wins.
- Demonstrated creative visualization skills (sketching/storyboarding) alongside CAD for fixtures/stations (SolidWorks, Creo, NX, or similar).
- Hands-on experience with assembly, machining, stamping, molding, casting, sheet metal, or electronics build; comfort on the shop floor.
- Strong grasp of lean tools (VSM, SMED, 5S, PFMEA, control plans, standard work) and line design (material presentation, kitting, conveyance, supermarkets).
- Data fluency (Excel; PowerBI a plus) for time studies, capacity modeling, and ROI cases.
- Excellent facilitation & storytelling-you can lead a room, sketch live, and make complex tradeoffs simple.
- Bias to action with tight follow-through from concept to pilot to scale.
Bonus Points- Experience with 3P, Toyota Kata/Shingo-aligned systems, or large-scale greenfield/brownfield layout work.
- Ergonomics & safety assessments; human factors in station design.
- Right-sized automation: collaborative robotics, low-cost automation, or simple PLC/HMI literacy.
- Exposure to MES/IIoT for real-time visibility and sustainment.
Benefits Overview:- Competitive salary
- Paid time off including vacation days and holidays
- Healthcare, dental, vision, and life insurance plans
- Generous company 401K contribution
