Continuous Improvement Manager - Pursuit

MBI - Malibu Boats, Inc

Town of Florida (NY)

On-site

USD 120,000 - 160,000

Full time

14 days+

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Job summary

Malibu Boats, Inc seeks a Continuous Improvement Site/Brand Lead to drive operational excellence across Pursuit manufacturing operations in Fort Pierce, FL. You will reduce COPQ, lead problem solving, and deploy Lean principles while maintaining Malibu’s premium craftsmanship and brand standards.

You will partner with Engineering, Production, Quality, and Supply Chain to elevate FPY, DPU, and warranty metrics, coaching teams on root-cause analysis and standardized work to ensure durable

Qualifications

Bachelor’s degree in engineering, manufacturing, operations, or related field.
8–10+ years in manufacturing and continuous improvement.
Strong experience driving quality improvement and COPQ reduction.
Experience in marine, automotive, or high‑mix assembly environments preferred.
Solid project management, organizational, and analytical skills.
Excellent communication, training, and facilitation.

Responsibilities

Own COPQ reduction strategy across the plant.
Lead structured problem-solving using A3, RCA, 8D, DMAIC.
Facilitate cross-functional problem-solving workshops.
Establish COPQ metrics and dashboards daily.
Lead Lean deployment to protect premium quality.
Partner with Engineering, Production, Quality, and Supply Chain.

Skills

Root cause solving

COPQ analysis

Lean manufacturing

Cross-functional leadership

Data-driven decisions

Education

Bachelor's degree in engineering or related field

Tools

QMS tools

Job description

Job Location: Pursuit FL - Fort Pierce, FL 34946

Summary

The 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 Responsibilities

Cost of Poor Quality (COPQ) Reduction & Problem Solving (PRIMARY DELIVERABLE)

Own plant-wide COPQ reduction strategy, including:

Baseline accuracy
Internal 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 thinking
Root Cause Analysis (RCA)
8D / DMAIC methodologies

Facilitate cross‑functional problem‑solving activities (workshops, coaching, training, etc.) on top external (warranty) and internal (plant losses), including:

Inspection
Rework
Gelcoat and cosmetic defects
Upholstery rework
Electrical and functional system failures

Ensure 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 Manufacturing

Lead continuous improvement initiatives across key brand/site production processes:

Parts and component assembly
Fiberglass hull/deck layup
Upholstery and interior finishing
Rigging (electrical, ballast, surf systems)
Final assembly, detailing, and water testing

Improve 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 controls
Visual Management for production and quality performance
5S in high‑visibility, finish‑critical areas
Layered Process Audits (LPA)
Optimal setup and controls leading to defect and COPQ reduction

Target waste reduction in:

Resin and composite material usage
Rework loops and repair stations
Labor inefficiencies driven by variation

Quality & Brand Protection

Partner 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:

Safety
Performance
Customer‑visible quality

Connect plant metrics directly to dealer and customer satisfaction.

Customer & Dealer Experience Integration

Translate 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 Systems

Establish plant‑wide SQDC and COPQ visual management systems.

Track and drive key KPIs:

COPQ as % of sales
Rework hours per boat
FPY and/or DPU
Warranty cost per unit
Throughput and on‑time delivery

Lead daily Gemba and tiered accountability meetings.

Production Scaling

Support 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 Building

Support 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 & Execution

Lead 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.

Qualifications

Education & Experience

Bachelor’s degree in engineering, Manufacturing, Operations, or related field.
8–10+ years of experience in manufacturing, continuous improvement, and/or operational excellence activities
Strong 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 concepts

Skills & Knowledge

Deep expertise in:

Root cause problem solving (A3, 8D, DMAIC)
COPQ analysis and budgetary impact modeling
Lean manufacturing principles

Experience 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 Competencies