Address
Form of workSUMMARY
To lead bold change through the Lean Manufacturing initiative at the site to ensure continuous, systemic, and sustainable elimination of waste through developing a fully engaged culture of Continuous Improvement (zero waste mindset), execution of Kaizen Events linked to the site Vision and annual Strategy Deployment and building of foundational capability for long term sustainment.
Create a vision that directs change efforts at the site and develops strategies / action plans to achieve the vision. Eliminate barriers to change and modify systems / processes as required in support of Lean principles (on demand, defect free, one by one, at lowest cost).
ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned.
QUALIFICATIONS
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
EDUCATION
BA / BS (4-year technical or business) degree preferable
EXPERIENCE
10 years plus of Manufacturing & Operations experience
Must have Quality & Lean Leadership Experience
SKILLS/ABILITIES
LANGUAGE / COMMUNICATION SKILLS
Excellent verbal skills
MATHEMATICAL SKILLS
Strong mathematical skills
REASONING ABILITY
Ability to recognize equipment/fabrication anomalies, and trouble shoot.
CERTIFICATES, LICENSES, REGISTRATIONS
Quality & Lean Leadership
PHYSICAL DEMANDS / WORK ENVIRONMENT
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
TRAVEL REQUIREMENTS
Ability to travel occasionally domestically, within PGT facilities including WinDoor location.
Occasional: Travel - Approximately 20%
To lead bold change through the Lean Manufacturing initiative at the site to ensure continuous, systemic, and sustainable elimination of waste through developing a fully engaged culture of Continuous Improvement (zero waste mindset), execution of Kaizen Events linked to the site Vision and annual Strategy Deployment and building of foundational capability for long term sustainment.
Create a vision that directs change efforts at the site and develops strategies / action plans to achieve the vision. Eliminate barriers to change and modify systems / processes as required in support of Lean principles (on demand, defect free, one by one, at lowest cost).
ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned.
- SITE LEADERSHIP
- Mentor, facilitator and lean practitioner
- Be the change agent - actively engage leadership and team members in the deployment process of Continuous Improvement.
- Annual planning of Kaizen Event activities to support Site Strategy Deployment plan based on Value Stream Mapping, Waste Analysis & Model Line Implementation.
- Quarterly priority setting of Kaizen Events to deliver step change in results (60 - 90-day outlook) at the target pace for the site
- Approval of Kaizen events & 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 Kaizen Events
- Approval of standards, systems, and processes to support sustainable execution
- Approval of site standards as related to Lean methodologies and implementation
- Implement a standardized and disciplined approach to problem solving across the organization
- DAILY / ACTIVE WASTE ELIMINATION COACHING
- Implement a daily accountability process for operations to highlight opportunities for Continuous Improvement while ensuring leadership is aligned.
- 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 Production Boards to ensure proper cascade of measures, targets, and actions from Leadership to shopfloor
- Identify and lead training in accordance with the needs defined by the Senior leadership, Site Strategy Deployment, and personal observation (daily coaching and walk throughs). Ensure proper understanding of these tools / techniques and ownership of deployment.
- KAIZEN EVENT FACILITATION
- Drive the site to model a Learn by Doing approach
- Organize / facilitate Kaizen Event-based and specific tool training for all monthly Kaizen Event teams
- Coordinate Preparation, Execution, and Follow-Up stages of the Kaizen Event process through weekly interaction with Leaders / Co-Leaders to ensure team is on pace with the guidelines / expectations of Kaizen Methodology.
- For Kaizen 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 (Kaizen events, 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, PM, Plan-Do-Check-Act, and other lean tolls defined in our production system.
- Coordinate Kaizen event Training 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 Kaizen Events within the site or within other facilities as required.
- REAPPLICATION / BENCHMARKING
- Develop and facilitate Lean Manufacturing Annual Plans within the site the ensure best practices are shared and reapplied efficiently to accelerate results
- Actively participate in the leadership meetings - share successful improvements with the network for potential reapplication to accelerate Company results and be open to learning from other sites to reapply successful, sustained improvements
- Actively participate in benchmarking visits and improvement sharing
- Identify industries / companies / sites within the same geographic region to conduct external benchmarking based on performance and Lean journey progress
- STRATEGY DEPLOYMENT
- Develop model line implementation strategy for site execution
- Train and develop kaizen facilitators for each site
- Create and develop leader standard work for group leader and team leaders
- Utilize 5S and visual management strategies to create a model factory for teaching others
- Utilize metrics to drive daily performance and KPI's
- Focus online balancing and leveling tools in an effort to produce at takt time
QUALIFICATIONS
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
EDUCATION
BA / BS (4-year technical or business) degree preferable
EXPERIENCE
10 years plus of Manufacturing & Operations experience
Must have Quality & Lean Leadership Experience
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 teams
- 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
LANGUAGE / COMMUNICATION SKILLS
Excellent verbal skills
MATHEMATICAL SKILLS
Strong mathematical skills
REASONING ABILITY
Ability to recognize equipment/fabrication anomalies, and trouble shoot.
CERTIFICATES, LICENSES, REGISTRATIONS
Quality & Lean Leadership
PHYSICAL DEMANDS / WORK ENVIRONMENT
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
- Ability to stand for long hours
- Frequent use of eye, hand, and finger coordination enabling the use of manufacturing equipment
- Oral and auditory capacity enabling interpersonal communication as well as communication through automated devices such as the telephone.
- lifting on manufacturing floor of extrusion and panels.
- Manufacturing floor performing fabrication, assembly, and equipment upkeep.
TRAVEL REQUIREMENTS
Ability to travel occasionally domestically, within PGT facilities including WinDoor location.
Occasional: Travel - Approximately 20%
