6-12+ years in manufacturing/industrial engineering or advanced operations consulting with a proven track record of process redesign and cost reduction
Creative visualization skills in sketching and storyboarding, along with proficiency in CAD software like SolidWorks or Creo
Hands-on experience in assembly, machining, stamping, molding, or related manufacturing processes
Strong understanding of lean tools (e.g., VSM, 5S) and line design principles
Proficiency in data analysis tools like Excel; PowerBI knowledge is a plus
Exceptional facilitation and storytelling abilities to clarify complex ideas
Strong action-oriented mindset with a focus on executing from concept through to pilot and scale
Responsibilities
Lead collaborative ideation sessions to redesign manufacturing lines and improve material flow
Implement practical improvements such as line balancing and ergonomic layouts
Quickly visualize concepts through sketches, 3D models, or mockups
Conduct diagnostics like time studies and waste identification to pinpoint high-ROI improvements
Develop prototypes and detailed specifications for manufacturing aids
Utilize DFMA and lean practices to streamline processes and minimize variations
Measure project impact using cost analysis and key performance indicators
Oversee implementation by guiding operator trials and crafting executive summaries
Benefits
Paid time off for vacation and holidays
Comprehensive healthcare packages including dental and vision
Generous 401K contributions from the company
Performance bonuses based on individual and company goals
Access to tools and resources to facilitate optimal work performance
Full Job Description
Lead Manufacturing Process Innovation Consultant
Location: Auburn Hills, MI (Onsite) Team: Munro & Associates Type: Full-time
The Opportunity
We'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).
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
