The Lean Systems Coach will report to the Lean Systems Manager and be responsible for supporting the development and implementation of the company's Production System’s lean manufacturing programs. This role entails taking a hands-on approach on the shop floor to drive lean manufacturing culture, continuous improvement, cost optimization, problem solving, standardization, and other tools. The Lean Systems Coach will collaborate with team members from all levels of the organization to lead projects aimed at improving safety, minimizing production issues and costs, and enhancing vehicle quality. They will develop, implement, and maintain necessary tools, systems, and training to optimize engagement in ongoing operations performance improvement.
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Responsibilities
- Ensure the company's Production System principles are implemented across all operational areas
- Optimize employee engagement in all the company's Production System programs
- Assist in eliminating roadblocks to continuous improvement
- Train and coach all levels and functions in lean principles and their applications
- Facilitate LPS program review meetings
- Conduct layered audits and process reviews
- Lead and support departmental Gemba walks
- Monitor departmental performance and analyze data to identify focused opportunities for reducing costs and improving productivity, utilization, and quality
- Support manufacturing initiatives to meet factory performance objectives in all key performance areas
- Develop, implement, and maintain lean tools, systems, and procedures for lean programs, with a focus on problem solving, performance management, continuous improvement, 6S (5S plus Safety), and standardization
- Champion regular Kaizen workshops with cross-functional teams to implement continuous improvement opportunities
- Utilize Business Process Automation tools for operational performance monitoring
- Manage work instruction software ensuring standard compliance and controlling necessary changes
Requirements
- Bachelor’s Degree in Engineering required; Industrial, Mechanical, Production Engineering preferred
- 3+ years of related experience required
- Experience in an automotive OEM is required
- Continuous improvement experience in automotive manufacturing; relevant lean role experience is a plus
- Strong understanding of manufacturing principles with expertise in both theory and hands-on practice
- Motivated individual with excellent interpersonal, written, and oral communication skills
- Skilled in coaching/mentoring for on-the-job application of new skills
- Ability to lead without formal authority
- Knowledge of production processes, costs, quality controls, logistics, and other manufacturing areas
- Familiarity with TPM, Autonomous Maintenance, Preventative Maintenance, or similar programs
- Experience in Kaizen Event Facilitation
- Strong problem-solving skills, including but not limited to 8D methodology
- Proficient in lean techniques such as time studies, data analysis, capacity analysis, and work instruction development
- Strong presentation skills with proficiency in Microsoft Office suite
- Familiar with industrial engineering techniques such as time studies, data analysis, capacity analysis, and work instruction development.
