Continuous Improvement Manager

Willcox Matthews; Warsaw (IN); On-site; USD 120,000 - 150,000; Full time

Job summary

Willcox Matthews is seeking a Lean CI Manager to drive the company’s Lean Six Sigma program across Warsaw, Indiana. This role reports to Operations leadership and focuses on coaching teams, delivering breakthrough improvements, and embedding CI into daily management.

The ideal candidate has a strong Lean toolbox, proven project leadership on DMAIC and Kaizen events, and is fluent in statistical analysis to guide data-driven decisions on cost, quality, and delivery improvements.

Qualifications

• Bachelor's degree in Engineering, Manufacturing, or a related technical field.
• Six Sigma Black Belt preferred; Green Belt minimum.
• 10 years’ hands-on Lean Six Sigma deployment experience.

Responsibilities

• Drive deployment of Business System and Lean Six Sigma practices across local value streams.
• Lead DMAIC projects and Kaizen events to reduce variation and improve lead times.
• Coach shop floor and salaried teams; promote continuous improvement culture.

Skills

Lean Six Sigma

Black Belt

Green Belt

Gemba Coaching

Statistical Analysis

Data-driven decisions

Education

Bachelor's degree in Engineering/Manufacturing

Tools

Takt

VSM

PULL

Standard Work

TPI

Hoshin Kanri

TWI

Job description

We’re supporting our client, a leading metal manufacturer based in Warsaw, Indiana who are looking for a Lean CI Manager to join their growing team. The successful Lean CI Manager will have experience in Lean Six Sigma deployment as well as advanced knowledge of critical Lean tools.

Job Summary:

As a Lean CI Manager, you’ll drive deployment of the company’s Business System and Lean Six Sigma practices across local value streams to deliver measurable operational excellence. Reporting to the Head of Operations USA and the Global Head of Operational Excellence, you will act as a change agent at the shop floor Gemba, coach and build capability across shop-floor and salaried/office teams, and lead high-impact DMAIC projects and Kaizen events that reduce variation, improve lead time, and deliver sustained cost, quality, and delivery improvements.

Responsibilities:

• Apply Business System Lean House steps and tools to drive operational excellence in manufacturing and transactional areas.
• Facilitate Strategic Planning and Strategy Deployment (Hoshin Kanri) across sites and value streams.
• Live and promote the 14 guiding principles of Business System Lean Leadership; be a visible change agent at the Gemba.
• Lead, facilitate and sponsor Breakthrough Kaizen events that deliver significant, measurable results.
• Drive strong employee engagement through structured programs, including cross‑functional teams (CFTs).
• Challenge Value Stream Managers and SMLT leaders to optimize performance and meet targets.
• Implement Standard Work using an 8 step approach:
• Product selection
• Capacity validation
• Define current state (time observations & SWCS)
• Define future state (to be SWCS)
• Confirm optimized SWCS (SOP/SOS)
• Sustain, review and continuously improve standard work
• Deploy Training Within Industry (TWI): Job Instruction, Job Methods, Job Relations.
• Coach teams to sustain standards and embed CI into daily management.
• Apply Value Stream Mapping (VSM) and TPI methods to identify improvement opportunities in operational and transactional flows.
• Design and implement PULL systems and related takt‑based flows to reduce lead time and inventory, and improve throughput.
• Lead and apply DMAIC and Six Sigma problem‑solving to reduce variation and root‑cause key issues.
• Use statistical analysis and data‑driven methods for decision making and to validate improvements.
• Conduct training/coaching on DMAIC, basic and advanced statistics for salaried/office employees and leaders.
• Maintain and share timely MIS and project communications on progress, benefits and risks.
• Apply disciplined PDCA / project management steps for planning, executing and sustaining projects.
• Ensure clear project chartering, benefit tracking, risk mitigation and handover to process owners.
• Train, coach and mentor shop floor operators, SMLT leaders, salaried/office staff, VS leaders and cross‑functional teams.
• Establish governance cadence for Business System deployment, project reviews, and KPI follow‑up.
• Role model continuous improvement behaviours and embed a culture of problem solving.

About You:

• Bachelor’s degree in Engineering, Manufacturing, Industrial Engineering, Chemistry, or related technical discipline
• Six Sigma Black Belt (preferred) or equivalent certification; Green Belt minimum.
• 10 years’ hands‑on experience in Lean Six Sigma deployment, preferably from Automotive, Engineering, Foundry, Chemical, Cement, Rubber, Medical, Pharma or Energy.
• Proven record of leading high‑impact Lean and/or Six Sigma (DMAIC) projects and breakthrough kaizen events.
• Practical implementation experience at shop floor/Gemba level and in transactional processes.
• Advanced knowledge of critical Lean tools (Takt, VSM, PULL, Standard Work, TPI, Hoshin Kanri, TWI).
• Facilitative leadership and change‑agent mindset; proactive about driving sustained improvement.
• Coaching, training and capability‑building proficiency (operators, SMLT, salaried/office).
• Stakeholder influence, governance and project management (PDCA) skills.
• Flexible, adaptable to dynamic change and timelines.
• Strong communication and presentation skills; fluent in English, Spanish and advantage