Director - Continuous Improvement - Volvo Group - Macungie

Job description
Director of Continuous Improvement provides leadership and direction to drive the implementation of Lean Manufacturing principles throughout all operations and processes; coordinates the development and implementation of the Volvo Production System to support meeting stated business objectives for Safety, Quality, Delivery, Cost and Morale; and mentors a team that supports the business in implementing the new work methods.

Core Responsibilities

• Continuously develops reviews and standardizes production system tools and methods in close cooperation with Plant management. Coordinates and manages cross functional teams for that purpose
• Defines, engineers and implements efficient and reliable Lean Manufacturing processes to guarantee efficient movement and delivery of materials and increase productivity and quality in station in support of production rates
• Develops training material and manages the organization and delivery of training sessions and workshops to all levels in the organization
• Continuously drives culture change and acceptance of Lean Manufacturing principles across the organization by communicating and demonstrating the values and practicality of continuous improvement
• Engages plant management and employees in conceptualizing, planning and implementing, and sustaining continuous improvements using the Volvo Production System and Lean Manufacturing tools
• Develops and coordinates implementation plans with management based on an agreed priority list. Frequently follows up with appropriate stakeholders to ensure timely and effective implementation and sustainability
• Creates and maintains a set of indicators to monitor the progress and sustainability of the lean activities. Drives continuous improvement -, kaizen- and problem solving activities using Lean Manufacturing tools and processes
• Coordinates internal assessments and external audits in cooperation with the global VPS team and local management
• Participates in global meetings and builds a network in and outside the company to share best practice
• Implements additional functionality and appropriate metrics to ensure full accountability for continuous improvements throughout the paint, material handling and build processes
• Develops direct and indirect reports to build functional and leadership capabilities
• Develops, maintains, implements and updates the Volvo Production System to support and enhance plant production capabilities
• Collaborates with Operations management to improve processes and evaluate and take action regarding day to day material, logistics, and build issues impacting the productions lines
• Identifies time critical and systemic material handling, paint and production issues and executes a resolution plan in a timely and successful manner
• Prepares monthly performance measurements to insure Manufacturing Systems Department is meeting its goals
• Manages Lean Engineers and associated personnel

Critical Competencies


• Ownership / Accountability: Taking the lead in getting the job done and accepting responsibility for personal actions, costs, and results
• Leadership: Setting and modeling high performance standards and empowering a team of people to achieve agreed-upon outcomes
• Teamwork: Building cooperation among individuals and departments, sharing information and resources, and working to achieve group goals and outcomes
• Lean Concept Advocate: Implement Lean Manufacturing and Flow values, foster the continuous improvement of all operational and business practices
• Creativity/Innovation: Reframing traditional patterns of thinking and applying new and evolving ideas, methods, designs and technologies
• Problem Solving/Decision Making: Taking a well-ordered approach to solving problems and acting despite obstacles or resistance
• Detailed knowledge of business and manufacturing productivity improvement practices, tools, methods and line balancing techniques
• Able to effectively develop a vision, plan, and coordinate the activities of the Manufacturing Production Systems group with Production, Materials, Quality, other Engineering functions, and the UAW
• Passionate for lean manufacturing and has an in-depth understanding of manufacturing systems
• Experienced project leader
• Proven analytical skills and sound structured approach
• International experience is an advantage
• Strong communicator who can influence his/her environment and be passionate about change and improvement
• Ability to work in a matrix and team based environment
• Resilience and perseverance: Ability to focus and execute projects to conclusion in the face of adversity and ambiguity
• Excellent computer skills; proficient in Excel, Power Point and Word.
• Strives for perfection; proven ability to manage large projects and maintain attention to detail
• Fosters diversity and promotes the development of staff members through mentoring/coaching and empowerment to increase skill sets and talent levels of the team

Minimum Education And Experience


• Bachelor’s Degree in Engineering, Manufacturing, Management or related field
• Master’s degree in Engineering, or MBA preferred
• 5 years or more experience with lean implementation in assembly environments
• Solid and proven project management skills required
• A demonstrated understanding of Lean principles such as Value Stream Mapping, Just-In-Time, Demand Flow, Single Piece Flow, Five S’s, Visual Management, Total Productive Maintenance, Continuous Improvement Process, Kaizen, SPC, Six Sigma and Communication Tools, Statistical Problem Solving and QS9000
• Six Sigma Black Belt Certification preferred
Travel Required (maximum)Occasional

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