Continuous Improvement​/Operational Excellence Specialist

At Morgan Advanced Materials
, our rich history and dedication to innovation define who we are. Since our establishment in the UK in 1856, we have expanded globally, now operating across 70 sites in 18 countries.

Our goal is to create a more sustainable world and enhance quality of life. We actively pursue this purpose through the development and production of advanced materials.

Within our business unit, we specialise in innovating cutting-edge carbon, graphite, and carbide products that deliver outstanding performance. We use our expertise to tackle complex challenges across many diverse industries to provide effective solutions for our valued customers.

Our products are shaping a better future; from enabling electric cars to charge faster and drive longer distances to maximising the operational efficiency of wind turbines. We are proud to help generate power for billions of people, deliver water to drought-stricken regions, improve the efficiency of industrial pumps, and protect lives both on the land and in the air.

Key Figures:Revenue £1,100.7m (2024), ~8,000 employees, manufacturing in 20+ countries, and a global customer portfolio. A UK PLC with head office located in Windsor, Berkshire UK. Listed on London Stock Exchange;
Member of the FTSE 250 Index.

The Continuous Improvement (CI) / Operational Excellence (OPEX) Specialist is responsible for driving operational performance and business results through the implementation of Lean Manufacturing, Operational Excellence, and data-driven improvement initiatives. This role partners with plant leadership, production teams, engineering, quality, supply chain, and support functions to identify opportunities, eliminate waste, improve processes, and optimize productivity.

The CI/OPEX Specialist will utilize Power BI, manufacturing KPIs, and statistical analysis to provide actionable insights, monitor plant performance, and support strategic decision-making. This position serves as a change agent, fostering a culture of continuous improvement throughout the facility.

Essential Functions:

Operational Excellence & Continuous Improvement

• Lead and facilitate Lean Manufacturing and Continuous Improvement initiatives across the facility.
• Drive improvements using Lean, Six Sigma, Kaizen, 5S, TPM, Standard Work, Visual Management, and Root Cause Analysis methodologies.
• Conduct value stream mapping and process observations to identify waste, bottlenecks, and inefficiencies.
• Facilitate Kaizen events, improvement workshops, and problem-solving sessions.
• Partner with production, maintenance, engineering, quality, and supply chain teams to implement sustainable process improvements.
• Develop and maintain process documentation, standard work instructions, and best practices.
• Monitor and measure the effectiveness of implemented improvements and report results to leadership.
• Promote a culture of continuous improvement and employee engagement at all levels of the organization.

Data Analytics & Business Intelligence

• Develop, maintain, and enhance Power BI dashboards, scorecards, and reporting tools.
• Analyze manufacturing data to identify trends affecting safety, quality, delivery, productivity, and cost.
• Design and automate KPI reporting for plant leadership and operational teams.
• Create visualizations that provide real-time insights into plant performance.
• Utilize ERP, MES, quality, maintenance, and production systems to collect and analyse operational data.
• Identify opportunities for automation and improved reporting efficiency using Microsoft Power Platform tools.
• Support strategic and operational decision-making through advanced data analysis.

Manufacturing Performance Improvement

• Support initiatives to improve:
  • OEE (Overall Equipment Effectiveness)
  • Labor productivity
  • Throughput
  • First Pass Yield
  • Scrap and rework reduction
  • Downtime reduction
  • Inventory optimization
  • On-time delivery performance
• Conduct root cause investigations utilizing methodologies such as:
  • A3 Problem Solving
  • Fishbone Diagrams
  • 5 Why Analysis
  • Pareto Analysis
  • Statistical Process Analysis
• Collaborate with engineering and operations teams to establish performance improvement targets and action plans.

Project Management

• Lead and manage improvement projects from identification through implementation and sustainability.
• Develop project charters, timelines, success metrics, and financial justifications.
• Communicate project status and results to plant leadership and stakeholders.
• Track cost savings, productivity gains, and operational benefits…