Sr. Lean Manager

A Senior Lean Manager responsible for driving continuous improvement initiatives across manufacturing operations to enhance productivity, quality, cost efficiency, and delivery performance. This role leads to the deployment of Lean Manufacturing, Six Sigma, and Operational Excellence strategies within an EMS environment, ensuring alignment with customer expectations and business objectives. They work cross-functionally to identify inefficiencies, develop strategic improvement plans, and lead teams to deliver sustainable operational enhancements.

This leadership role demands expertise in Lean tools, strong analytical abilities, and exceptional coaching and communication skills.

Essential Job Elements
• Lead and implement Lean, Six Sigma, and Kaizen initiatives across production, engineering, quality, and support functions.
• Identify improvement opportunities through data analysis (OEE, FPY, scrap, cycle time, etc.).
• Execute and facilitate Value Stream Mapping (VSM) and process optimization projects.
• Drive a culture of continuous improvement at all organizational levels.
• Improve key performance indicators (KPIs).
• Develop and implement standard work, process controls, and best practices.
• Reduce waste in all forms (defects, overproduction, waiting, motion, inventory, transport, over-processing).
• Champion Lean methodologies (5S, SMED, Kanban, Poka-Yoke).
• Lead Six Sigma DMAIC projects to reduce process variation and defects.
• Train and mentor Green Belts, Yellow Belts, and front-line teams.
• Ensure sustainability of improvements through audits and governance.
• Collaborating with Production, NPI, Quality, and Engineering teams to improve processes
• Drive cycle time reduction and line balancing initiatives.
• Support design for manufacturability (DFM) and process capability improvements.
• Promote use of MES, ERP, and manufacturing analytics tools.
• Develop dashboards and performance tracking systems.
• Enable data-driven decision-making across operations.
• Identify and execute cost-saving projects (labor efficiency, scrap reduction, material optimization).
• Support budgeting and cost improvement targets.
• Lead change management initiatives to sustain operational excellence culture.
• Coach and mentor managers and supervisors in Lean thinking and problem-solving.
• Promote accountability, engagement, and cross-functional collaboration.
• Ensure alignment with industry standards (ISO 9001, ISO 13485, IATF 16949 if applicable).
• Support audits and compliance initiatives.
• Reinforce a strong quality mindset across the organization.

Job Knowledge, Skills, Qualifications & Abilities
• Lead and manage multiple Lean projects simultaneously across various departments.
• Develop, implement, and sustain continuous improvement strategies aligned with organizational goals.
• Analyze operational data to identify bottlenecks and areas for waste reduction.
• Conduct Lean training sessions and workshops to educate employees at all levels.
• Facilitate Gemba walks and lead Kaizen events to promote rapid and incremental improvements.
• Collaborate with department heads and cross-functional teams to integrate Lean methodologies organization-wide.
• Mentor and coach personnel in Lean tools and problem-solving techniques.
• Create and maintain comprehensive Lean project documentation and report progress to senior leadership.
• Establish and track key performance indicators (KPIs) to measure the effectiveness and impact of Lean initiatives.
• Drive cultural change to embed a mindset of continuous improvement within the workforce.

Experience/Education
• Bachelor’s degree in Engineering, or a related field or equivalent education and/or years of experience.
• Minimum of 5-7 years of experience in Lean Management or continuous…