Continuous Improvement Manager - Malibu Boats

Job Location

Malibu TN - Loudon, TN 37774

The Continuous Improvement (CI) Site/Brand Lead is responsible for driving operational excellence across assigned MBI manufacturing operations, supporting the end-to-end operations, including production of premium boats and marine components. This role partners closely with plant and MBI leadership to enhance performance in hull fabrication, assembly, upholstery, rigging, and finishing—while preserving the craftsmanship and brand quality MBI is known for. A core accountability of this role is the reduction of Cost of Poor Quality (COPQ) through disciplined problem‑solving, defect elimination, and process control.

The CI Lead acts as a hands‑on change agent, deploying feasible methodologies (that include Lean principles) in a high‑customization environment while strengthening a culture of accountability and continuous improvement.

• Own plant‑wide COPQ reduction strategy, including:
  • Baseline accuracy
  • Internal failures (scrap, rework, repair hours)
  • External failures (warranty, dealer claims, field issues)
  • Extended appraisal costs (inspection inefficiencies)
• Align with MBI Quality initiatives by co‑establishing brand/site baseline COPQ metrics and drive year‑over‑year reduction targets.
• Lead structured problem‑solving activities by using:
  • A3 thinking
  • Root Cause Analysis (RCA)
  • 8D / DMAIC methodologies
• Facilitate cross‑functional problem‑solving activities (workshops, coaching, training, etc.) on top external (warranty) and internal (plant losses), including:
  • Inspection
  • Rework
  • Gelcoat and cosmetic defects
  • Upholstery rework
  • Electrical and functional system failures
• Ensure permanent corrective actions with validation, standardization, and follow‑up audits.
• Build capability across teams to solve problems at the root cause—not symptoms.
• Create transparency through COPQ dashboards and integrate into daily management.

• Lead continuous improvement initiatives across key brand/site production processes:
  • Parts and component assembly
  • Fiberglass hull/deck layup
  • Upholstery and interior finishing
  • Rigging (electrical, ballast, surf systems)
  • Final assembly, detailing, and water testing
• Improve flow and reduce bottlenecks in large‑product, station‑based assembly.
• Optimize takt alignment and line balancing in high‑mix production.

• Implement Lean tools while protecting Malibu’s premium quality standards:
  • Standard Work with built‑in quality controls
  • Visual Management for production and quality performance
  • 5S in high‑visibility, finish‑critical areas
  • Layered Process Audits (LPA)
  • Optimal setup and controls leading to defect and COPQ reduction
• Target waste reduction in:
  • Resin and composite material usage
  • Rework loops and repair stations
  • Labor inefficiencies driven by variation

• Partner with MBI Quality to protect the premium brand reputation.
• Improve first‑pass yield (FPY), reduce defects per unit (DPU), and reduce defect escape rates.
• Drive mistake‑proofing (poka‑yoke) in critical systems affecting:
  • Safety
  • Performance
  • Customer‑visible quality
• Connect plant metrics directly to dealer and customer satisfaction.

• Translate dealer feedback and warranty trends into actionable improvement plans.
• Close the loop between field issues and plant corrective actions.
• Prioritize improvements that enhance the on‑the‑water customer experience.

• Establish plant‑wide SQDC and COPQ visual management systems.
• Track and drive key KPIs:
  • COPQ as % of sales
  • Rework hours per boat
  • FPY and/or DPU
  • Warranty cost per unit
  • Throughput and on‑time delivery
• Lead daily Gemba and tiered accountability meetings.

• Support ramp‑up/down aligned to demand cycles.
• Improve workforce flexibility via cross‑training and standard work.
• Maintain quality discipline during high‑volume peak periods.

• Support growth of problem‑solving capability at all levels of the organization.
• Coach supervisors and team leaders on structured CI and defect…