Continuous Improvement Manager

Hexatronic Rochester Cable Inc; Culpeper (VA); On-site; USD 95,000 - 140,000; Full time

Job summary

Hexatronic Rochester Cable Inc. seeks a Continuous Improvement Manager to lead Lean deployment across the site and drive sustained operational excellence. You will partner with Production, Quality, Engineering, Maintenance, and Supply Chain to improve safety, quality, delivery, and cost performance.

You will spend significant time on the shop floor, coach teams, and run Kaizen events to convert ideas into durable improvements using PDCA and standard work.

Qualifications

• Bachelor’s degree in Engineering, Manufacturing, Operations Management, Business, or related discipline, or equivalent relevant experience.
• At least five years of experience leading continuous improvement in a manufacturing environment.
• Experience with TPM, Value Stream Mapping, Kaizen facilitation, SMED, 8D, FMEA, and process auditing.
• Experience in cable manufacturing, extrusion, wire processing, or another complex industrial manufacturing environment.
• Experience with digital visual management, action tracking, manufacturing data, or operational performance dashboards.

Responsibilities

• Lead facility-wide deployment and sustainment of Lean practices.
• Plan and facilitate Kaizen events and cross-functional projects.
• Coach leaders and teams in Lean leadership and problem solving.
• Maintain shop-floor engagement and a blameless, data-driven culture.
• Improve safety, quality, delivery, productivity, and cost performance.

Skills

Lean manufacturing

Root cause analysis

PDCA

Standard work

5S

Value stream mapping

Kaizen facilitation

Leadership

Team coaching

Education

Bachelor’s degree in Engineering/Manufacturing/Operations Management or related

Tools

8D

FMEA

Fishbone diagrams

SMED

KPIs/dashboards

Job description

Job SummaryThe Continuous Improvement Manager leads and sustains operational excellence across Rochester Cable by embedding Lean thinking, disciplined problem solving, employee engagement, and leader development into daily work. This hands-on leader partners with Production, Quality, Engineering, Maintenance, Supply Chain, Safety, and site leadership to improve safety, quality, delivery, productivity, equipment reliability, material flow, and cost performance.Success in this role requires a highly visible shop-floor presence, strong follow-through, practical coaching, and the ability to build trust with operators and leaders. The manager listens first, explains the “why,” creates a blameless learning environment, and converts employee ideas into sustainable improvements through PDCA and standard work.Essential Job Duties/Functions (Not all inclusive)Lean Deployment and Operating SystemLead facility-wide deployment and sustainment of Lean manufacturing and continuous improvement practices.Establish and improve 5S, visual controls, standard work, process mapping, Value Stream Mapping, Total Productive Maintenance, and Leader Standard Work.Facilitate tiered accountability routines that create clear escalation, ownership, committed actions, and follow-through.Plan and facilitate Kaizen events and cross-functional improvement projects focused on safety, quality, delivery, productivity, flow, and cost.Use PDCA and process audits to confirm that new methods work as designed and remain sustained.Shop-Floor Engagement and CultureMaintain a consistent daily presence in Gemba across shifts, including regular contact with operators, supervisors, and support functions.Listen to employees, understand process barriers, solicit improvement ideas, and help teams implement practical solutions.Build credibility with shop-floor leaders by serving as a responsive support resource and reliably closing commitments.Promote a blameless, fact-based environment focused on process inputs, learning, accountability, and prevention.Coach employees and leaders so Lean tools become the way work is managed, not a separate program.Spend significant time on the manufacturing floor and work across shift boundaries when business needs require.Problem Solving and Quality ImprovementLead and coach structured root-cause analysis using 5 Why, 8D, Fishbone diagrams, FMEA, and related methods.Support Stop-the-Line and escalation processes for safety, quality, equipment, and delivery risks.Partner with Quality and Operations to prioritize chronic losses, implement corrective and preventive actions, and verify effectiveness.Maintain visibility of problem-solving actions and metrics through approved tracking systems and management routines.Support process and compliance audits, including setup-sheet adherence, calibration status, job alerts, CUI handling, and other defined process controls.Material Flow and Operational ReadinessImplement and optimize Kanban, supermarket, point-of-use material, and replenishment systems.Improve next-job readiness, changeover performance, production flow, work-in-process control, and schedule responsiveness.Collaborate with Supply Chain and Production to map processes, eliminate handoff gaps, and strengthen material and information flow.Leadership Development and TrainingCoach and mentor leaders and teams in Lean leadership, facilitation, problem solving, and improvement management.Develop and deliver practical training in Lean fundamentals, Eight Wastes, standard work, Gemba, 5S, PDCA, and root-cause tools.Bring cross-functional teams together, align stakeholders on the improved future state, clarify roles, and communicate the purpose behind each change.Provide a Continuous Improvement introduction during new-hire onboarding and reinforce relevant process-handling requirements.EducationBachelor’s degree in Engineering, Manufacturing, Operations Management, Business, or a related discipline, or equivalent relevant experience.Work ExperienceAt least five years of experience leading continuous improvement or operational excellence initiatives in a manufacturing environment.Experience with TPM, Value Stream Mapping, Kaizen facilitation, SMED, 8D, FMEA, and process auditing.Experience in cable manufacturing, extrusion, wire processing, or another complex industrial manufacturing environment.Experience with digital visual management, action tracking, manufacturing data, or operational performance dashboards.Required Skills and CompetenciesDemonstrated application of Lean manufacturing, structured problem solving, standard work, visual management, and change leadership.Proven ability to facilitate cross-functional teams and coach employees at multiple organizational levels.Strong communication, interpersonal, presentation, analytical, and project-management skills.Preferred QualificationsLean Six Sigma Green Belt, Black Belt, or equivalent Lean certification.Working knowledge of ISO-based management systems and corrective-action processes.