Regional Continuous Improvement Manager, West
Morgan Truck Body, Janesville, WI, United States
Regional Continuous Improvement Manager
The Regional Continuous Improvement Manager will deploy and execute the Pondexter Lean Production System (PLPS) across a region comprising approximately six plants. The role entails identifying and implementing process improvements tied to Key Performance Indicators (KPIs) using Lean and Continuous Improvement tools, and may require hands‑on shop floor work to sustain improvements.
Key Duties & Responsibilities
Document current processes and propose improvements through Kaizen events, value‑stream mapping, and problem‑solving tools.
Standardize processes across business units, developing Standard Operating Procedures, work standards, and 5S activities; display manufacturing KPIs at all plants.
Implement process management and improvement initiatives following Lean and Continuous Improvement principles.
Create self‑sustaining processes and tracking systems utilizing appropriate manufacturing KPIs, Kaizen activities, and savings.
Train line staff and team members in Lean and Continuous Improvement tools and methodologies as part of project execution.
Lead process changes, value‑stream mapping, financial savings calculation, and validation.
Champion communication across manufacturing plants and between Morgan and its parent company.
Facilitate and lead cross‑functional teams to achieve Kaizen objectives.
Improve workflow efficiency and productivity through line balancing and waste elimination.
Mentor employees in Lean methodology and problem‑solving execution.
Publish progress reports.
Follow and comply with all Environmental Health & Safety policies.
Expertise (Must)
Bachelor’s degree in Business, Engineering or a related field.
5+ years of experience in discrete manufacturing applying Lean manufacturing and problem‑solving tools.
5+ years of experience in Lean and Continuous Improvement activities, including financial calculation of savings, budget forecasting, ROI calculation, and ratio analysis.
5+ years of experience implementing a visual factory (visual management) displaying real‑time information for team members and management.
Trained in Lean Six Sigma principles (5S, Waste Reduction, Error/Mistake Proofing, PDCA, Root Cause Analysis, A3 Problem Solving, VSM, Kaizen, Lead Time Reduction).
Strong analytical skills and extensive experience calculating financial savings and return on investment.
Experience in operational performance evaluation (Efficiency/Productivity/Utilization).
Ability to travel 50% to 75% of the time.
Expertise (Wish)
Six Sigma Certified (Green or Black Belt).
Automotive or Aerospace experience.
Experience developing and maintaining Power BI dashboards (or similar tools) to visualize KPIs and support data‑driven decision making.
Proficiency in data analysis tools such as Excel (advanced formulas, Power Query, VBA) and/or Minitab.
Working knowledge of CAD software (e.g., AutoCAD, SolidWorks) for layout optimization and line balancing.
Experience with Manufacturing Execution Systems (MES) or ERP systems for production tracking and performance analysis.
Key Competencies
Effective oral and written communication, supporting employee involvement and strategic plans.
Collects and analyzes information relevant to problems, generates diverse solutions, and selects the best course of action.
Manages competing priorities, resourcefulness, and time efficiently.
Builds relationships and develops highly effective teams and alliances inside and outside the organization.
Makes timely decisions using well‑developed judgment, considering alternatives, risks, and critical factors.
Applies analytical thinking to problem identification, solution development, and implementation.
Sets and achieves challenging goals, persistent under difficulties, and demonstrates urgency in goal attainment.
Proven knowledge and execution of Lean methods modeled after the Toyota Production System.
Safety
Safety is paramount. The manager is expected to be familiar with and enforce the company’s safety program and policies, ensuring compliance at all times.
Physical Requirements
Job operates in a manufacturing plant environment. Requires standing, walking, using hands to handle or feel, reaching, and lifting and carrying objects up to 30 pounds.
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The Regional Continuous Improvement Manager will deploy and execute the Pondexter Lean Production System (PLPS) across a region comprising approximately six plants. The role entails identifying and implementing process improvements tied to Key Performance Indicators (KPIs) using Lean and Continuous Improvement tools, and may require hands‑on shop floor work to sustain improvements.
Key Duties & Responsibilities
Document current processes and propose improvements through Kaizen events, value‑stream mapping, and problem‑solving tools.
Standardize processes across business units, developing Standard Operating Procedures, work standards, and 5S activities; display manufacturing KPIs at all plants.
Implement process management and improvement initiatives following Lean and Continuous Improvement principles.
Create self‑sustaining processes and tracking systems utilizing appropriate manufacturing KPIs, Kaizen activities, and savings.
Train line staff and team members in Lean and Continuous Improvement tools and methodologies as part of project execution.
Lead process changes, value‑stream mapping, financial savings calculation, and validation.
Champion communication across manufacturing plants and between Morgan and its parent company.
Facilitate and lead cross‑functional teams to achieve Kaizen objectives.
Improve workflow efficiency and productivity through line balancing and waste elimination.
Mentor employees in Lean methodology and problem‑solving execution.
Publish progress reports.
Follow and comply with all Environmental Health & Safety policies.
Expertise (Must)
Bachelor’s degree in Business, Engineering or a related field.
5+ years of experience in discrete manufacturing applying Lean manufacturing and problem‑solving tools.
5+ years of experience in Lean and Continuous Improvement activities, including financial calculation of savings, budget forecasting, ROI calculation, and ratio analysis.
5+ years of experience implementing a visual factory (visual management) displaying real‑time information for team members and management.
Trained in Lean Six Sigma principles (5S, Waste Reduction, Error/Mistake Proofing, PDCA, Root Cause Analysis, A3 Problem Solving, VSM, Kaizen, Lead Time Reduction).
Strong analytical skills and extensive experience calculating financial savings and return on investment.
Experience in operational performance evaluation (Efficiency/Productivity/Utilization).
Ability to travel 50% to 75% of the time.
Expertise (Wish)
Six Sigma Certified (Green or Black Belt).
Automotive or Aerospace experience.
Experience developing and maintaining Power BI dashboards (or similar tools) to visualize KPIs and support data‑driven decision making.
Proficiency in data analysis tools such as Excel (advanced formulas, Power Query, VBA) and/or Minitab.
Working knowledge of CAD software (e.g., AutoCAD, SolidWorks) for layout optimization and line balancing.
Experience with Manufacturing Execution Systems (MES) or ERP systems for production tracking and performance analysis.
Key Competencies
Effective oral and written communication, supporting employee involvement and strategic plans.
Collects and analyzes information relevant to problems, generates diverse solutions, and selects the best course of action.
Manages competing priorities, resourcefulness, and time efficiently.
Builds relationships and develops highly effective teams and alliances inside and outside the organization.
Makes timely decisions using well‑developed judgment, considering alternatives, risks, and critical factors.
Applies analytical thinking to problem identification, solution development, and implementation.
Sets and achieves challenging goals, persistent under difficulties, and demonstrates urgency in goal attainment.
Proven knowledge and execution of Lean methods modeled after the Toyota Production System.
Safety
Safety is paramount. The manager is expected to be familiar with and enforce the company’s safety program and policies, ensuring compliance at all times.
Physical Requirements
Job operates in a manufacturing plant environment. Requires standing, walking, using hands to handle or feel, reaching, and lifting and carrying objects up to 30 pounds.
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