Continuous Improvement Manager

United Alloy; Janesville (WI); On-site; USD 110,000 - 206,000; Full time

Job summary

An established industry player seeks a Continuous Improvement Manager to spearhead the implementation of Lean methodologies. This pivotal role focuses on optimizing production processes and fostering a culture of continuous improvement across multiple facilities. The ideal candidate will leverage their expertise in Lean tools and data analytics to drive operational excellence and ensure sustainable performance improvements. Join a dynamic team dedicated to innovation and efficiency, where your contributions will significantly impact the manufacturing landscape. If you are passionate about driving change and enhancing productivity, this opportunity is perfect for you.

Benefits

Medical insurance

Vision insurance

401(k) plan

Qualifications

• 5+ years of experience in continuous improvement within manufacturing.
• Proven success in Lean Operating System design and deployment.

Responsibilities

• Lead Lean Operating System implementation to optimize production processes.
• Collaborate with cross-functional teams to enhance operational efficiency.

Skills

Lean methodologies

Root cause analysis

Data analytics

Leadership skills

Communication skills

Education

Bachelor's degree in Industrial Engineering

Lean Six Sigma Black Belt certification

Tools

Excel

Minitab

Power BI

Job description

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The Continuous Improvement Manager will lead the development and implementation of a Lean Operating System to drive operational excellence at United Alloy, a premier manufacturer of metal fabrication and assembly solutions. Based in Janesville, WI, this role will focus on optimizing production processes, eliminating waste, and fostering a culture of continuous improvement through advanced Lean methodologies. The successful candidate will collaborate with cross-functional teams across United Alloy’s facilities to align initiatives with strategic manufacturing goals, ensuring sustainable performance improvements and operational efficiency.

The role can be based out of our Janesville Wisconsin, Seguin Texas, or Union Ohio facilities.

ESSENTIAL DUTIES & RESPONSIBILITIES:

Lean Operating System Design & Implementation:

• Develop and deploy a standardized Lean Operating System tailored to United Alloy’s metal fabrication and assembly operations.
• Embed Lean principles (e.g., value stream mapping, 5S, Kaizen, Kanban, SMED, Poka-Yoke, Heijunka) as foundational elements of production workflows.
• Create tools, templates, and metrics to sustain Lean practices across United Alloy’s Janesville and other facilities.

Process Optimization:

• Identify inefficiencies, bottlenecks, and waste in manufacturing processes using Lean tools and root cause analysis techniques (e.g., 5 Whys, Fishbone Diagrams, Pareto Analysis).
• Lead value stream mapping initiatives to streamline production flows, reduce lead times, and improve throughput for United Alloy’s custom metal products.
• Implement solutions to enhance product quality, equipment uptime, and shop floor productivity.
• Facilitate Kaizen events, Gemba walks, and rapid improvement workshops to drive immediate and long-term gains at United Alloy’s Janesville and other sites.
• Coach manufacturing teams on Lean principles, fostering a proactive problem-solving culture across all United Alloy facilities.
• Develop and deliver training programs on Lean tools, root cause analysis, and continuous improvement methodologies for United Alloy employees.

Performance Measurement:

• Define and monitor manufacturing KPIs (e.g., OEE, cycle time, defect rates) to evaluate the effectiveness of the Lean Operating System at United Alloy.
• Leverage data analytics to uncover trends, perform root cause analysis, and identify improvement opportunities in production processes.
• Report progress and impact to the Director of Lean & Advanced Manufacturing, linking outcomes to United Alloy’s business objectives.

Cross-Functional Collaboration:

• Partner with United Alloy’s production, quality, supply chain, and engineering teams to align Lean initiatives with manufacturing goals across all facilities.
• Drive adoption of Lean practices across shop floors and support functions, acting as a change agent within the Janesville facility and beyond.

Sustainability & Scalability:

• Ensure Lean processes are sustainable and scalable to support United Alloy’s growth and diverse product lines across all manufacturing sites.
• Establish auditing and feedback mechanisms to refine and maintain the Lean Operating System at United Alloy.

QUALIFICATIONS:

• Bachelor’s degree in Industrial Engineering, Manufacturing, Operations Management, or related field.
• 5+ years of experience in continuous improvement or Lean implementation within manufacturing environments, preferably in metal fabrication or assembly.
• Proven success in designing and deploying Lean Operating Systems in production settings.
• Certifications such as Lean Six Sigma Black Belt, Kaizen Facilitator, or equivalent required.
• Expertise in Lean tools (e.g., value stream mapping, 5S, SMED, Kanban, Poka-Yoke, Heijunka, Takt Time, Andon) and root cause analysis (e.g., 5 Whys, Fishbone Diagrams, Pareto Analysis).
• Strong analytical skills with proficiency in manufacturing data tools (e.g., Excel, Minitab, ERP systems, Power BI).
• Exceptional leadership, communication, and change management skills to engage United Alloy’s shop floor and leadership teams.
• Ability to influence and drive Lean adoption in a fast-paced manufacturing environment.
• 12 Expected Behaviors of Actively Engaged Person – 100% Responsible, Trustworthy, Team Player, Clear Communicator, Empathy, Humility, Emotional Self-Control, Resolves Conflict Directly, Positive Attitude, Respects Others, Problem Solver, and Agile.

Preferred Skills:

• Experience with metal fabrication, welding, or assembly processes relevant to United Alloy’s operations.
• Knowledge of advanced manufacturing technologies (e.g., automation, IoT, Industry 4.0).
• Familiarity with TPM (Total Productive Maintenance) and OEE optimization.
• Experience with project management methodologies (e.g., Agile, PMP).
• Full-time role requiring regular presence on the manufacturing shop floor at United Alloy’s Janesville, WI facility.
• Approximately 20% travel to other United Alloy factories to support Lean initiatives and ensure consistency across sites.

Compensation:

• Competitive salary commensurate with experience, plus United Alloy’s comprehensive benefits package.

Seniority level

• Seniority level

  Mid-Senior level

Employment type

• Employment type

  Full-time

Job function

• Job function

  Management and Manufacturing

• Industries

  Industrial Machinery Manufacturing

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Inferred from the description for this job

Medical insurance

Vision insurance

401(k)

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