Lean Continuous Improvement Manager (Detroit Thermal Systems)

Piston Automotive; Romulus (MI); On-site; USD 90,000 - 120,000; Full time

Job summary

Detroit Thermal Systems in Romulus, MI seeks a Continuous Improvement Manager to lead plant-wide CI initiatives targeting Safety, Quality, Delivery, Cost, and People (SQDCP). The role standardizes IE processes and develops Manufacturing Engineers to build capability.

You will drive Lean manufacturing systems, coach teams in Kaizen events, develop KPI management, and partner with Operations, Quality, Maintenance and Supply Chain to sustain improvements and ensure process readiness for new

Qualifications

• Bachelor’s degree in Industrial Engineering or related field.
• 7+ years of manufacturing experience with a focus on CI and IE.
• Experience deploying Lean systems and structured problem-solving.
• Proven ability to train and develop technical teams.
• Strong analytical and data-driven decision making.

Responsibilities

• Lead plant-wide continuous improvement initiatives aligned to SQDCP performance targets.
• Develop and standardize IE processes, tools, and methodologies.
• Coach cross-functional teams in Kaizen events and problem-solving workshops.
• Establish KPI management systems with clear ownership and timelines.
• Collaborate with Operations, Quality, Maintenance, and Supply Chain to sustain improvements.
• Drive throughput, reduce inventory, optimize flow, and improve productivity.

Skills

Continuous Improvement

Industrial Engineering

Lean manufacturing

Data analytics

Education

Bachelor’s degree in Industrial Engineering or related field

Tools

Time studies

Line balancing

Capacity analysis

Job description

Detroit Thermal Systems- Continuous Improvement Manager

is responsible for leading plant-wide continuous improvement initiatives with primary accountability for driving performance improvements across Safety, Quality, Delivery, Cost, and People (SQDCP).

This role establishes and standardizes core Industrial Engineering (IE) processes and standards while developing Manufacturing Engineers to build IE capability over time.

Responsibilities

ESSENTIAL DUTIES AND RESPONSIBILITIES ( Include but are not limited to):

Continuous Improvement Leadership (~70%):

• Lead plant-wide continuous improvement aligned to Piston Group’s CI / Lean Strategy to improve business objectives and SQDCP performance targets
• Drive implementation and sustainment of Lean manufacturing systems, including daily management, standard work, and waste elimination
• Identify and eliminate operational losses using data, structured problem solving, and root cause analysis
• Coach and lead cross-functional teams in Kaizen events, problem-solving workshops, and improvement projects
• Establish and sustain KPI management systems, including tiered accountability and performance escalation processes
• Drive continuous improvement initiatives focused on throughput, inventory reduction, flow optimization, and productivity improvement
• Ensure alignment and integration of CI activities with plant operations, quality, maintenance, and supply chain functions
• Lead development of a continuous improvement culture through training, coaching, and leadership engagement
• Track and report improvement initiatives with clear ownership, timelines, and measurable impact

Industrial Engineering Systems (~30%):

• Define, develop, and standardize core Industrial Engineering processes, tools, and methodologies across the plant
• Establish standards for:
• Labor planning and line balancing
• Standard work and work measurement
• Capacity analysis and modeling
• Layout optimization and material flow design
• Partner with Manufacturing Engineering to deploy IE standards into production environments
• Train and coach Manufacturing Engineers to develop core IE competencies and ownership of these processes
• Provide hands-on support and mentoring on IE tools, including time studies, line balancing, and throughput analysis
• Support development of engineered labor standards and productivity models aligned with financial and operational targets
• Ensure sustainability of IE practices through documentation, audits, and governance routines
• Support engineered labor standards and productivity models

Operational Performance & KPI Management

• Drive measurable improvements in safety, quality, delivery, cost, and productivity metrics
• Utilize data analytics to identify performance gaps and prioritize improvement initiatives
• Establish performance baselines, targets, and tracking mechanisms for CI and IE initiatives
• Support operational reviews with leadership by presenting progress, risks, and results

People Leadership & Development

• Coach, mentor, and develop cross-functional team members in CI and IE disciplines
• Build organizational capability in Lean tools, structured problem-solving, and industrial engineering fundamentals
• Foster a culture of accountability, data-driven decision-making, and continuous improvement
• Support leadership teams in driving engagement and adoption of CI methodologies across all levels

Safety, Quality & Compliance

• Ensure all CI and IE activities align with plant safety and quality standards
• Support root cause analysis and corrective actions related to safety incidents and quality issues
• Drive compliance with company policies, procedures, and regulatory requirements

Cross-Functional Collaboration

• Partner with Operations, Quality, Maintenance, Manufacturing Engineering, and Materials teams to drive performance improvements
• Support new program launches by ensuring process readiness, capacity alignment, and efficient production flow
• Act as a key interface between CI strategy and shop-floor execution

Qualifications

REQUIRED EDUCATION & EXPERIENCE

• Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, Operations, or related field
• Minimum 7+ years of experience in manufacturing, with strong emphasis on Continuous Improvement and Industrial Engineering
• Demonstrated experience deploying Lean manufacturing systems and structured problem-solving methodologies
• Experience developing and implementing Industrial Engineering standards and processes
• Proven ability to train, coach, and develop technical teams
• Strong analytical and data-driven decision-making skills

Preferred Qualifications

• Automotive industry (OEM or Tier 1) experience
• Six Sigma Black Belt or Lean certification
• Experience in high-volume, complex manufacturing environments
• Experience in unionized manufacturing environments
• Exposure to advanced manufacturing and automation environments