Flow Optimization Manager

Ford Motor • Chicago, IL

3d • Onsite

About The Position

The Flow Manager is a high-impact leadership role responsible for the end-to-end optimization of vehicle assembly operations. Unlike a traditional Area Manager focused on daily output, the Flow Manager is the architect of efficiency. This individual drives the integration of Lean Manufacturing, Six Sigma methodologies, and Industrial Engineering principles to eliminate waste, maximize labor value-added (VA) time, and ensure the seamless movement of material and product through the plant.

Requirements

• Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, Operations Management, or related field
• 5+ years of experience in manufacturing operations, production engineering, or industrial/process improvement roles
• Proven experience leading flow optimization initiatives in a high-volume Final Assembly environment is preferred
• Demonstrated expertise applying Lean manufacturing principles, including waste identification, standard work optimization, and takt-based flow
• Strong data analytics capabilities, including the use of dashboards and tools such as Power BI, Tableau, SQL, or advanced Excel for process performance monitoring
• Solid understanding of Final Assembly production processes, material flow, line balance, and station design
• In-depth knowledge of the Quality Operating System (QOS), including layered audits, control plans, and defect tracking systems
• Working knowledge of End-of-Line (EOL) testing procedures, test systems performance tracking, and test failure analysis
• Experience conducting time studies, and bottleneck analysis
• Familiarity with process control methodologies (SPC)
• Lead and oversee all functions of the Plant's Maintenance Control Center (MCC)
• Strong ability to collaborate with cross-functional partners, including Quality, Production Engineering, Maintenance, and Operations
• Demonstrated success driving continuous improvement and change management initiatives
• Excellent project management skills with the ability to lead multiple priorities simultaneously
• Strong communication skills with the ability to present performance insights and recommended actions to leadership
• Data-driven decision-maker with strong root cause problem-solving skills (e.g., 5-Why, A3, fishbone analysis)
• Bias for action and a continuous improvement mindset

Nice To Haves

• Master’s degree
• Validated ability to resolve diverse issues and conflict situations
• Strong ability to lead a large organization; interface/manage plant hourly personnel, salaried personnel, and contract personnel
• Lean Manufacturing/Six Sigma Black Belt experience
• Proven ability to communicate and present to diverse audiences
• Strong analytical skills and quick decision-making capability
• Competent in the use of data for decision-making
• Aspiration for continued growth and new challenges
• Demonstrated leadership with outstanding interpersonal, team building, and communication skills

Responsibilities

• Value Stream Mapping implementation and waste stream optimization
• LMM implementation and workgroup engagement ownership
• Standard work / Spider diagram analysis and value/non-value movement improvement
• GAP to Engineer Running Capacity analysis and improvement implementation
• Vehicle inventory management with First Run Capability vs MTTR analysis
• Primary focus is on waste elimination at the workstation level
• Lead and oversee all functions of the Plant's Maintenance Control Center (MCC)

Benefits

• Immediate medical, dental, and prescription drug coverage
• Flexible family care, parental leave, new parent ramp-up programs, subsidized back-up childcare and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members, and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time

What This Job Offers

• Job Type: Full-time
• Career Level: Manager