The Operational Excellence Manager is responsible for driving our transition to a Lean culture in the plant, ensuring a high level of commitment and excitement with Lean plant experts, plant leadership and floor employees to exceed the business objectives. This role is fundamental in supporting and leading productivity improvements, and loss elimination initiatives in the plant. Success is measured by the ability to actively engage our plant to achieve tangible results and to educate teams in waste elimination and Continuous Improvement (CI) using Lean Principles. We need someone with exceptional influence, management skills and a proven record of successfully directing employees who are not direct reports. This role will report to the Plant Manager.
Responsibilities:
- Knowledge of, understanding of and compliance to all QOD's that are associated with your job description.
- Actively participate in Lean, Quality, Product Safety, SQF (Safe Quality Foods), and Workplace Safety Programs.
- Utilization of CI/Lean tools, processes, and systems.
- Lead Kaizen events, follow up on action items, analyze and re-evaluate outcomes through hands-on participation.
- Analyze reporting and communication of departmental key metrics related to continuous improvements, and Environmental, Health and Safety performance.
- Drive Key Performance Indicators (KPI) by utilizing Lean Principles to analyze systems and create action plans to improve them.
- Ensure Lean activities are linked to the business objectives and develop a site transformation plan in collaboration with the site management team.
- Ensure pre-event training, preparation for events, development and implementation of a communication plan, post-event follow-up and auditing of results, prompt delivery of supplies and materials, and mentoring KPO team members.
- Understand and apply financial drivers and Key Performance Indicators (KPI).
- Lead team to develop and maintain engineering competencies at the sites by coaching and mentoring to build capabilities.
- Teach Lean tools to all levels of the organization (Kaizen, 5S, TPM, Set-up reduction, Standard Work, Visual Management, SQDC boards, MDI, etc.).
- Work with a wide variety of corporate leadership, department management, site associates, and outside vendors to drive improvement in Safety, Quality, production efficiency, costs, and loss reduction.
- Provide overall support, assistance, direction, and communication to management teams regarding CI initiatives.
- Partner and mentor Multi-Color manufacturing leadership in Lean techniques, resulting in transformational progress.
- Build and maintain the foundation for continuous improvement by ensuring the effective functioning of transformation activities aligned to a Lean Operating System.
- Foster a culture of moving forward in a change environment and assuring buy-in and ownership at all levels.
- Share best practices to drive results and capability to development consistency.
- Maintain overall program tracking for impact and cultural improvements.
- Perform relevant duties as assigned by Director of Quality and Operational Excellence.
Qualifications:
- BS - Engineering or Operations Management or equivalent experience is required.
- Lean Six Sigma experience is preferred.
- Five or more years of experience in plant leadership, with at least 2 years in a position responsible for driving Lean manufacturing initiatives in complex manufacturing facilities.
- Strong change management skills and demonstrated experience changing a culture to a Lean environment.
- Experience successfully leading and directing employees who are not direct reports.
- Experience in being a change agent leading complex transformational activities.
- Significant experience in implementing complex Lean principles as they apply to multiple manufacturing operations.
- Proven success designing, implementing, communicating, and meeting policy deployment goals, including improved through-put, shortened cycle time, improved inventory turns and reduced supply chain costs.
- Expertise in manufacturing the particular product materials or product type within the span of control of this position.
- Analytical, problem solver, technical troubleshooter skills, self-starter, communicator, leader.
- Experience leading technical resources to successfully maintain production line equipment to achieve high levels of productivity.
- Ability to work in an environment that encourages teamwork, participation, creativity, openness, honesty, and mutual respect.
- Participates in special projects and performs other duties as assigned.
- Personal experience participating in or leading more than 10 Kaizen events.
- At least one (1) successful transformational experience where Lean was used as part of the catalyst and foundation for the change either in focused transformational leadership role or as part of the Senior Operating team driving the change. Demonstrated impact that translated to clear, bottom line performance results with step-function change.
- Formal Lean training from an "academy" organization either through direct consulting experience (e.g. Shingijutsu, TBM) or via organizations with deep, well-established lean operating systems (e.g. Toyota, Danaher)
In Plant:
- The physical demands require standing, using hands to feel and touch; reach with arms and hands; talk and hear.
- This position requires frequent walking.
- Occasionally employee is required to climb or balance, stoop, kneel, crouch or crawl.
- Must be able to regularly lift or move up to 50 pounds.
- Specific vision requirements are close vision, distance vision, color vision, peripheral vision, depth perception and ability to adjust focus.
