Continuous Improvement Manager

We are seeking a results-driven Production Continuous Improvement Manager to coach teams in scientific problem-solving while delivering measurable operational improvements through Toyota Kata methodology. This hands-on role requires an individual who can develop improvement capabilities across production teams while executing targeted improvement projects that drive quantifiable results in our high-growth manufacturing environment.

Key Responsibilities

Toyota Kata Implementation & Coaching:

• Coach production teams through the Improvement cycle: understand current condition, establish target condition, conduct PDCA experiments, and reflect on learning
• Guide teams in setting appropriate challenge directions and target conditions aligned with production goals
• Facilitate daily coaching cycles with team leaders and supervisors to develop scientific thinking patterns
• Support teams in conducting rapid PDCA experiments on production processes, equipment performance, and workflow optimization
• Work hands-on with teams to identify obstacles preventing achievement of target conditions

Process Improvement & Results Delivery:

• Lead by example in applying Toyota Kata methodology to tackle complex production challenges while managing multiple concurrent improvement projects
• Guide teams through systematic problem-solving using Plan-Do-Check-Act cycles for cycle time reduction, yield improvement, and defect elimination
• Conduct detailed analysis of production lines, manufacturing processes, and workflow bottlenecks using Lean tools (5S, value stream mapping, standardized work)
• Execute targeted Six Sigma DMAIC projects when appropriate, integrated with Toyota Kata experimentation approach
• Perform hands-on root cause analysis using statistical tools and data analysis to solve production problems

Performance Measurement & Learning Documentation:

• Establish and track production KPIs including OEE (Overall Equipment Effectiveness), cycle time, defect rates, and throughput
• Monitor progress toward target conditions and coach teams through obstacle identification and countermeasure development
• Generate monthly reports showing both cost savings/productivity improvements and team learning progression
• Maintain coaching records and experiment logs to track learning and capability development
• Validate improvement results through statistical analysis and control charts

Capability Development & Culture Building:

• Develop improvement kata and coaching kata capabilities in leadership
• Train production teams on scientific thinking, experimentation mindset, and learning from failure
• Create and maintain coaching cycles with team leaders across production areas
• Establish improvement kata practice routines while ensuring sustainability of implemented improvements
• Coach front-line supervisors on both Toyota Kata methodology and traditional Lean problem-solving tools

Required Qualifications:

• Bachelor's degree in industrial engineering, Manufacturing Engineering, Business Administration, or related field
• 7+ years hands-on experience in production environments implementing continuous improvement methodologies
• Toyota Kata certification or demonstrated experience with Improvement Kata and Coaching Kata methodologies
• Lean Six Sigma Black Belt certification preferred, or equivalent demonstrated proficiency with Lean tools and statistical analysis
• Strong coaching and mentoring skills with ability to develop scientific thinking in others
• Experience with PDCA experimentation, hypothesis testing, and systematic problem-solving approaches
• Proficiency with statistical analysis software and data visualization tools
• Demonstrated track record of delivering measurable results in manufacturing operations
• Strong project management skills with ability to manage multiple concurrent initiatives

Preferred Qualifications:

• Experience in aerospace, defense, automotive, or high-precision manufacturing
• Knowledge of advanced manufacturing concepts
• Familiarity with ERP systems and manufacturing execution systems
• Certification in project management (PMP) or change management

Working Environment:

• This role requires 80% time on the production floor working directly with manufacturing teams.
•  Hands-on problem solving, data collection, and implementation activities in an active manufacturing environment.