Continuous Improvement Manager - MBG

Maverick Boat Group Inc; Florida; On-site; USD 120,000 - 160,000; Full time

Job summary

Maverick Boat Group Inc. seeks a Continuous Improvement Site/Brand Lead to drive operational excellence across its manufacturing operations, including hull fabrication, assembly, upholstery, rigging and finishing.

You will act as a hands-on change agent, deploying Lean principles to reduce COPQ and improve quality while preserving premium craftsmanship. The role partners with plant leadership to establish COPQ metrics, lead RCA and 8D/DMAIC activities, facilitate cross-functional problem

Qualifications

• Bachelor’s degree in engineering, manufacturing, operations or related field.
• 8–10+ years of experience in manufacturing CI/operational excellence.
• Lean Six Sigma Green/Black Belt preferred.
• Strong project management, analytical, and communication skills.
• Experience with data analysis and modern QA/QMS tools.

Responsibilities

• Own COPQ reduction strategy with baseline metrics and year-over-year targets.
• Lead structured problem-solving using A3, RCA, 8D, and DMAIC methodologies.
• Facilitate cross-functional problem-solving workshops and coaching.
• Drive CI projects across engineering, production, quality and supply chain.
• Establish and manage visual management (SQDC) and COPQ dashboards.

Skills

Root Cause Analysis

Cross-functional leadership

Lean manufacturing

Project management

Data-driven decision making

Change management

Communication

Education

Bachelor’s degree in engineering/Manufacturing/Operations or related field

Tools

QMS tools

Job description

SummaryThe Continuous Improvement (CI) Site/Brand Lead is responsible for driving operational excellence across assigned MBI manufacturing operations, supporting the end-to-end operations, including production of premium boats and marine components. This role partners closely with plant and MBI leadership to enhance performance in hull fabrication, assembly, upholstery, rigging, and finishing—while preserving the craftsmanship and brand quality MBI is known for.A core accountability of this role is the reduction of Cost of Poor Quality (COPQ) through disciplined problem-solving, defect elimination, and process control. The CI Lead acts as a hands-on change agent, deploying feasible methodologies (that include Lean principles) in a high-customization environment while strengthening a culture of accountability and continuous improvement.Key ResponsibilitiesCost of Poor Quality (COPQ) Reduction & Problem Solving (PRIMARY DELIVERABLE)Own plant-wide COPQ reduction strategy, including:Baseline accuracyInternal failures (scrap, rework, repair hours)External failures (warranty, dealer claims, field issues)Extended appraisal costs (inspection inefficiencies)Align with MBI Quality initiatives by co-establishing brand/site baseline COPQ metrics and drive year-over-year reduction targets.Lead structured problem-solving activities by using:A3 thinkingRoot Cause Analysis (RCA)8D / DMAIC methodologiesFacilitate cross-functional problem-solving activities (workshops, coaching, training, etc.) on top external (warranty) and internal (plant losses), including:InspectionReworkGelcoat and cosmetic defectsUpholstery reworkElectrical and functional system failuresEnsure permanent corrective actions with validation, standardization, and follow-up audits.Build capability across teams to solve problems at the root cause—not symptoms.Create transparency through COPQ dashboards and integrate into daily management.Operational Excellence in Premium Boat ManufacturingLead continuous improvement initiatives across key brand/site production processes:Parts and component assemblyFiberglass hull/deck layupUpholstery and interior finishingRigging (electrical, ballast, surf systems)Final assembly, detailing, and water testingImprove flow and reduce bottlenecks in large-product, station-based assembly.Optimize takt alignment and line balancing in high-mix production.Lean Deployment (Craftsmanship + Efficiency)Implement Lean tools while protecting Malibu’s premium quality standards:Standard Work with built-in quality controlsVisual Management for production and quality performance5S in high-visibility, finish-critical areasLayered Process Audits (LPA)Optimal setup and controls leading to defect and COPQ reductionTarget waste reduction in:Resin and composite material usageRework loops and repair stationsLabor inefficiencies driven by variationQuality & Brand ProtectionPartner with MBI Quality to protect the premium brand reputation.Improve first-pass yield (FPY), reduce defects per unit (DPU), and reduce defect escape rates.Drive mistake-proofing (poka-yoke) in critical systems affecting:SafetyPerformanceCustomer-visible qualityConnect plant metrics directly to dealer and customer satisfaction.Customer & Dealer Experience IntegrationTranslate dealer feedback and warranty trends into actionable improvement plans.Close the loop between field issues and plant corrective actions.Prioritize improvements that enhance the on-the-water customer experience.Performance Management & Visual SystemsEstablish plant-wide SQDC and COPQ visual management systems.Track and drive key KPIs:COPQ as % of salesRework hours per boatFPY and/or DPUWarranty cost per unitThroughput and on-time deliveryLead daily Gemba and tiered accountability meetings.Production ScalingSupport ramp-up/down aligned to demand cycles.Improve workforce flexibility via cross-training and standard work.Maintain quality discipline during high-volume peak periods.Culture & Capability BuildingSupport growth of problem-solving capability at all levels of the organization.Coach supervisors and team leaders on structured CI and defect elimination.Drive accountability for “build it right the first time” mindset.Increase employee engagement in kaizen and continuous improvement.Project Leadership & ExecutionLead a pipeline of CI projects with measurable impact on COPQ and operational performance.Partner with Engineering, Production, Quality, and Supply Chain.Ensure sustainability through standard work, audits, and leader standard work.#MaverickBoatGroupEducation & ExperienceBachelor’s degree in engineering, Manufacturing, Operations, or related field.8–10+ years of experience in manufacturing, continuous improvement, and/or operational excellence activitiesStrong experience driving quality improvement and cost of poor-quality reduction required.Demonstrated performance and experience in marine, automotive, RV, or other high-mix assembly environments preferred.Strong project management, organizational, and analytical skills.Excellent communication, training, and facilitation abilities.Experience with data analysis, modern QMS tools, and advanced manufacturing conceptsSkills & KnowledgeDeep expertise in:Root cause problem solving (A3, 8D, DMAIC)COPQ analysis and budgetary impact modelingLean manufacturing principlesExperience with industry materials and finishing processes strongly preferred.Lean Six Sigma certification (Green/Black Belt) preferred.Strong leadership, team building, group facilitation, and change management skills.Key CompetenciesAccountability, dependability, adaptability, and flexibilityCoaching, mentoringCreative, innovative thinkerGood decision making and judgmentEthics, integrity, honestyWillingness to learnRelentless focus on defect elimination and root cause resolutionPassion for craftsmanship and premium product qualityData-driven decision-making with strong shop-floor instinctsAbility to lead in high-variation, custom manufacturingStrong cross-functional leadership and influenceSystems thinking and standardizationProject management and executionTraining and capability developmentAttention to detail and documentation rigorChange managementSuccess MetricsActivity based transformational resultsYear-over-year reduction in COPQ (% of revenue)Reduction in rework hours and defect ratesImproved first-pass yield and DPU across all production stagesDecrease in warranty claims and field failuresIncreased throughput without quality degradationSupport improvement of on-time delivery performanceSustained cost savings tied to defect elimination