Director of Operational Excellence

North American Stamping Group•Portland, TN

About The Position

The Director of Operational Excellence reports to the VP of Engineering and is responsible to lead the development, implementation, and ongoing improvement of a sustainable Operational Excellence Culture. Champions sustainable continuous improvement utilizing the Total Quality Production System (TQPS) business model to drive and deliver safety, quality, production, cost, and service targets for external and internal customers. Serves as a coach and mentor for operational leadership at all levels in the TQPS business philosophy and discipline. The Director will partner with each plant’s leadership teams to develop, strategize, and implement continuous improvement initiatives that support organizational goals that eliminate waste, cut costs, and increase production and profitability.

Requirements

BS / BA with emphasis in Engineering, Business Administration, Operations Management, or related technical discipline.
Training or certification in applying Lean/Six Sigma and/or TPS principles and methodologies.
10-15 years of progressive experience in a supply chain and/or manufacturing operations environment.
5-10 years of management role with supervisory responsibilities.
10+ years "hands-on" experience in lean manufacturing process with a proven track record of delivering results.
Minimum 5 years’ experience developing strategic plans supportive of senior leadership visions.
Must have implemented lean practices in several different plants or operating environments.
Prior experience with multi-site responsibility in a manufacturing setting.
Strong problem-solving ability using a DMAIC, PDCA, or 8D structure.
Understands the Lean concepts of Flow, Pull, and Waste Elimination Principles within the end-to-end integrated Supply Chain.
Capable of leading and implementing the practical application of the full range of lean methods on the plant floor.
Proven, demonstrated skill and abilities in developing, driving, and executing end-to-end Value Stream Mapping with tangible levels of success and results.
Thorough understanding and application of Lean/Six Sigma and Continuous Improvement principles, techniques, methodologies, systems, and processes including PDCA, Kaizen, 5S, SMED, Standardized Work, 5-Why, Problem Solving, and Kanban.
Ability to recognize when to coach and mentor, lead and direct.
Must be an analytical thinker
Ability to use scientific method for problem solving
Decision making must be based on facts and data
Must be systems and process oriented
Must have a flexible schedule
Strong project management skills
Displays strategic and creative thought process
Strong presentation skills
Demonstrate a "Hands On" approach
Proven negotiation and mediation skills
Ability to work with a dynamic team and demanding customers
Must possess a clear understanding of our systems
Must possess a clear understanding of our manufacturing processes
Must be able to identify waste and generate ideas for engineering solutions
Must have a working knowledge of raw and component material specifications and characteristics commonly used in automotive manufacturing
Working knowledge of tool, fixture, gauge, welder, automation, and press processes
Ability to rapidly process and comprehend large amounts of detailed information to consider the implications and consequences of new facts and make decisions.
Thorough understanding of organization product, trade terminology, quality management and control systems and techniques, manufacturing processes including material controls, workflow, scheduling, kanban, and equipment and machine operation.

Nice To Haves

Master's degree in related field and/or Professional certification is preferred.
Lean/Six Sigma Master Black Belt a big plus.
Experience at an OEM and/or Tier 1/II supplier to automaker helpful.
Successful development and promotion of subordinates to senior level management positions.
Strong Tooling or Mechanical Engineering background preferred.

Responsibilities

Promotes and drives continuous improvement at all NASG group companies.
Cascade key related objectives from corporate strategic plan (Hoshin) into divisional strategies for operational excellence.
Develop detailed project plan while driving execution to enable the successful accomplishment of key annual first level objectives for year over year results.
Establish process design with continuous improvement to replicate strategic planning process throughout all other areas of the organization with mentoring of key leaders where needed.
Lead and drive systematic and sustainable Lean and Continuous Improvement activities to achieve net productivity, cost of production, safety, quality targets, overall equipment effectiveness (OEE), world class service and delivery performance.
Drives the value stream mapping and improvement plan for each manufacturing site in the identification, selection, scope, and execution of projects, utilizing Key Process Indicators and Lean/Six Sigma methodologies.
Promotes and leads change by shifting paradigms.
Challenges status quo and demonstrates sustainable results projects.
Mentor leaders of all divisions and functional areas in the disciplines and skills of TQPS.
Provide guidance, direction, and coaching as it pertains to the designing of processes, recognition and solving of problems, and sharing of knowledge.
Develop curriculum and teach key lean tools when need for knowledge and application identified.
Ensure appropriate level of “connectivity” with manufacturing and non-manufacturing leadership regarding the successful expansion and execution of TQPS and Continuous Improvement Processes.
Foster engagement of leaders at all levels of organization, building a foundation for sustainable business results.
Promotes operational excellence through TQPS at all NASG locations.
Drives change by shifting paradigms.
Identify opportunity and improve design at corporate level for manufacturing and non-manufacturing processes with necessary mentoring of divisional leaders to promote capability to do the same.
Ensure that key metrics are defined, developed, and tracked and that improvements result in a positive impact for each project.
Execute complex continuous improvement projects and Kaizen Events as assigned to increase productivity, improve quality, and maximize profitability.
Makes recommendations for integrating TQPS/Lean/Six Sigma initiatives in partnership with various departments to drive projects to completion.
Assists in the identification of high impact projects within assigned Value Stream.
Develops problem solving leaders and teams throughout the organization to lead key projects and kaizen activities.
Guide the management for project sustainment with calculating relevant financial results.
Develop, coordinate, and conduct TQPS training and workshops to leadership and team members throughout all of NASG.
Develop standardized training / workshop packages for key operational excellence skill sets that include prespecified workshop packages, training material, deployment swim lanes and embedded tests to sustain results.
Through training and development assist all associates in bettering themselves in TQPS.
Foster associate involvement and engagement at all levels, building a foundation for sustainable business results.