Continuous Improvement Manager

Rochester Cable Inc.; Culpeper, Northern (VA, KY); Hybrid; USD 90,000 - 140,000; Full time

Job summary

Rochester Cable Inc. is seeking a Continuous Improvement Manager in Culpeper, VA to lead and sustain operational excellence using Lean, PDCA, and standard work.

The role partners with Production, Quality, Engineering, Maintenance, and Supply Chain to improve safety, quality, delivery, and cost performance. The ideal candidate will spend significant time on the shop floor, coach leaders, and drive practical improvements through structured problem solving and visual management.

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 or operational excellence initiatives in manufacturing, 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; familiarity with digital visual management and performance dashboards.

Responsibilities

• Lead 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, TPM, and Leader Standard Work.
• Facilitate Kaizen events and cross-functional improvement projects focusing on safety, quality, delivery, productivity, flow, and cost.
• Maintain a consistent daily presence on the shop floor across shifts and engage operators and support functions.
• Coach teams in Lean tools and structured problem solving to drive practical improvements.
• Partner with Quality and Operations to prioritize chronic losses and verify effectiveness of corrective actions.
• Develop leaders through Lean training, standard work, PDCA, and root-cause analysis.

Skills

Lean manufacturing

Structured problem solving

Standard work

Visual management

Change leadership

Education

Bachelor’s degree or equivalent experience

Job description

# Continuous Improvement ManagerCulpeper, VA 22701## OverviewPosition TypeFull TimeJob ShiftDayEducation LevelAssociate's DegreeTravel PercentageUp to 25%CategoryManufacturing## Continuous Improvement Manager****Job Summary****The 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 System***** Lead 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 Culture***** Maintain 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 Improvement***** Lead 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 Readiness***** Implement 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 Training***** Coach 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.## Qualifications****Education****Bachelor’s degree in Engineering, Manufacturing, Operations Management, Business, or a related discipline, or equivalent relevant experience.****Work Experience****At 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 Competencies***** Demonstrated 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 Qualifications***** Lean Six Sigma Green Belt, Black Belt, or equivalent Lean certification.* Working knowledge of ISO-based management systems and corrective-action processes.