Lean Leader

Johnson Controls•San Antonio, TX

1d•$80,000 - $110,000•Onsite

About The Position

As part of the JCI San Antonio Chillers manufacturing site, this role will own the Lean Transformation Journey of one of its three engineered-to-order and configured-to-order value streams. Reporting to the Lean Transformation Manager, the Lean Leader will work closely with the Value Stream Manager and their staff to drive the implementation of the Johnson Controls Business System. This hands-on role involves assessing current state performance, identifying gaps, developing future state visions, monitoring progress, and sharing best practices. The Lean Leader will define, design, and implement process improvements, ensuring integration across the organization and aligning projects with business strategies. They will facilitate and coach improvement teams, identify gaps in business metrics, and develop strategies for improvement with plant personnel. The role requires assessing operations using Value Stream Mapping and root cause analysis tools, developing future state visions, and driving implementation plans. A key responsibility is developing Lean capability by coaching staff in JCBS principles, strengthening problem-solving behaviors, operational discipline, and fostering a culture of continuous improvement. The Lean Leader will ensure the implementation and sustainment of the Daily Management system, perform time studies to re-balance operations and eliminate waste, and utilize 3P to create flow. They will modify physical and digital layouts, ensure process owner involvement in software development and team leadership, and manage improvement projects through the kaizen funnel. Collaboration with leadership to develop a plant Lean Transformation Roadmap is essential, driving breakthrough performance through improvements, Kaizens, and workshops. The role involves partnering with Process Owners to identify and remove systemic barriers, documenting learning, and sharing best practices. The Lean Leader will identify new project opportunities, partner with the Focus Factory Manager on strategic initiatives, and is accountable for delivering annual goals. The position also requires adherence to the Code of Conduct, Business Ethics, and driving Safety Performance.

Requirements

Bachelor’s degree required. Preferably in Engineering.
At least 5 years of professional working experience, with at least 2 years in a manufacturing operations role and 2 years in continuous improvement or lean manufacturing role.
Has at least 2 yrs of proven experience in indirect leadership, influencing an organization to drive Lean Transformation.
Possesses a Green Belt Six Sigma or a Lean Certification in Value Steam Mapping and Standard Work.
Demonstrated expertise in Lean tools and concepts: VSM, Kaizen facilitation, SMED, 5S, standard work, takt time, flow, pull systems.
Strong analytical and problem-solving skills with experience using A3 or similar methodologies.
Excellent communication, facilitation, and coaching skills.
Proficiency in Microsoft Suite Applications (Word, Excel, Access, & PowerPoint) as well as Internet software and E-mail is required.
Proficiency in Visio and/or any other software to create Value Stream Maps and Process Maps.
Proficiency in Autocad or similar software to create/modify site layouts.

Nice To Haves

Bilingual (English and Spanish)
2 yrs of experience in Shinguijutsu Events
Worked in an environment with a robust Continuous Improvement Business System

Responsibilities

Own the Lean Transformation Journey of one of its 3 engineered-to-order and configured-to-order value streams.
Report to the Lean Transformation Manager of the site and work very closely with the Value Stream Manager and its staff to drive the implementation of the Johnson Controls Business System.
Assess current state performance, identify gaps, visualize and establish a plan to get to the future state, monitor progress and share/acquire best-in-class ideas and systems.
Define, design and implement process improvement as part of the Johnson Controls Business System (JCBS); ensures integration and alignment vertically and horizontally across organization.
Define improvement projects aligned with business strategies and priorities.
Facilitate and coach improvement teams.
Identify gaps in business metrics and then works with all levels of the plant in establishing and executing a strategy for improving them.
Assess using Value Stream Mapping and root cause problem solving tools (such as A3, 5 Whys, Fishbone Diagram, etc) the current state of the plant’s Operations, develop Future State vision and drive and monitor the implementation plan.
Develop Lean capability across the value stream by coaching Focus Factory staff, front‑line leaders, and associates in JCBS principles, strengthening problem‑solving behaviors, operational discipline, and a culture of continuous improvement.
Ensure the implementation and sustainment of the Daily Management system at his/her respective value stream.
Perform time studies of the operations with the goal of re-balancing the operation and eliminate waste.
Utilize 3P as a tool to create flow at the site in the designated value stream.
Modify/update physical and digital layouts as required during the transformation of the site.
Ensure process owner involvement in SW development and team leadership.
Using kaizen funnel tracking and reporting systems, will prepare detailed plans, drive project performance, and assure timely completion and achievement of transformational and continuous improvement projects.
Collaborate with leadership to develop a plant Lean Transformation Roadmap, driving breakthrough or Best-in-class performance that balances resources between internal plant efficiency and external customer-focused effectiveness projects through 1. Just Do It improvements, 2. Kaizens, 3. Workshops.
Partner with Process Owners to identify systemic barriers to project success and strategically drive the organizational, process, and behavioral changes required to remove them.
Document improvement process learning and shares best practices throughout the NA Chillers Business plants and JCI as a whole.
Identify and bring forward to Champion new project opportunities.
Partner with the Focus Factory Manager on strategic initiatives that strengthen standards compliance, accelerate the deployment of new systems, and shape innovative, future-focused solutions that drive sustainable operational excellence across the plant.
Is accountable to deliver the Focus Factory and Plant annual goals.
All other tasks as assigned.
Adheres to the Company’s Code of Conduct and Business Ethics standards.
Responsible for driving Safety Performance in the Plant.