Operational Excellence Manager

Kaizen Talent Solutions; Coventry; On-site; GBP 90,000 - 120,000; Full time

Job summary

Kaizen Talent Solutions is seeking a hands-on Operational Excellence Manager for a heritage British manufacturing business in the West Midlands. You will lead a site-wide Lean transformation, balancing traditional craft with automation to improve flow and reduce lead times across the factory.

You will coach teams on value-stream transformation, standardise visual management, line balancing, and quality improvements while aligning NPI with capital plans.

Qualifications

• Proven Lean/CI transformations in complex manufacturing environments.
• Experience in high-mix production environments.
• Strong communication and coaching skills.

Responsibilities

• Lead end-to-end Lean transformation across the site to optimise flow and reduce lead times.
• Plan, facilitate and execute site-wide Kaizen events and coach teams on CI culture.
• Standardise and audit daily visual management to drive data-driven accountability across shifts.
• Conduct takt time/cycle time analyses to balance multi-station assembly lines and update SOPs.
• Partner with Quality to reduce defects and maximise first-time-through yield.
• Collaborate with Supply Chain to optimise Kanban, pull systems, and line-side logistics.
• Support NPI rollout and align Lean initiatives with capital equipment roadmap.

Skills

Gemba leadership

Lean transformation

Value Stream Mapping

5S/SMED/TPM

Line balancing

Problem solving (A3, 8D)

Data-driven decision making

Tools

Kanban systems

Job description

On behalf of a prestigious, heritage-rich British manufacturing business with centuries of engineering excellence, we are seeking a hands‑on, high-impact Operational Excellence Manager.

Following recently being acquired, the organisation is embarking on a comprehensive site-wide Lean transformation across its flagship West Midlands manufacturing facility. Employing several hundred site team members, the operation encompasses end-to-end capabilities from sheet‑metal fabrication through to advanced assembly and testing.

This role offers an exceptional opportunity to shape the operation of a traditional manufacturing hub. You will lead the Continuous Improvement and Lean agenda, balancing traditional craftsmanship with modern automation, improving flow, and driving a sustainable culture of Lean excellence.

KEY RESPONSIBILITIES

• Value Stream Transformation: Lead end-to-end Lean transformation across the site to optimise flow, reduce lead times, and enhance internal SQDC performance.
• Site Kaizen & CI Culture: Plan, facilitate, and execute site-wide Kaizen events (5S, waste reduction, SMED, TPM) and act as a hands‑on coach.
• Tiered Visual Management: Standardise and audit daily visual management cadences to drive data‑driven accountability across all shifts.
• Line Balancing & SOPs: Conduct takt time/cycle time analyses to balance multi‑station assembly lines and collaborate with Production Engineering to update SOPs.
• Quality & Scrap Reduction: Partner with Quality teams to eliminate root‑cause defects using structured methodologies (8D, 5 Whys, Fishbone) to maximise first‑time‑through yield.
• Line‑Side Logistics & Kanban: Work closely with supply chain to optimise point‑of‑use material feeds, implementing pull systems, Kanban, and kitting strategies.
• NPI & Capital Alignment: Support the operational rollout of Next Generation product launches while aligning Lean initiatives with the site's capital equipment roadmap.

CANDIDATE PROFILE

• We are seeking a Gemba‑focused, hands‑on leader who has experienced "what good looks like" in a World‑Class Manufacturing environment and possesses the passion and agility to apply those principles to a traditional manufacturing operation.
• Proven Track Record: Extensive experience delivering measurable Lean / CI transformations in complex, high‑mix industrial manufacturing environments.
• Lean Toolkit Expertise: Mastery of Value Stream Mapping (VSM), SMED, TPM, Cellular Manufacturing, and 7 Wastes elimination.
• Problem‑Solving Skills: Deep expertise in root‑cause problem‑solving (A3, 8D, Ishikawa, 5 Whys) within quality and scrap reduction contexts.
• Leadership & Influence: Outstanding communication skills with a proven track record of influencing and coaching colleagues at every level, from shop‑floor operators to executive leadership.
• Analytical & Data‑Driven: Strong proficiency in visual control systems, shop‑floor analytics, and data‑driven decision‑making.

WHAT THIS ROLE OFFERS

• Transformation Ownership: The platform to genuinely own and execute an end‑to‑end Lean roadmap supported by active investment and committed executive leadership.
• Impact & Visibility: High‑visibility leadership role key to driving the plant's transition into a competitive Centre of Excellence.
• Competitive Package: Attractive executive base salary, comprehensive benefits package, and long‑term career progression within a growing global group.