Senior Lean Manufacturing Specialist

Cornerstone Building Brands•Rocky Mount, VA

10d•$90,000 - $100,000•Onsite

About The Position

The Material Flow Pillar Lead is responsible for improving the end-to-end flow of material supporting the Model Line, from receiving and warehouse through point of use. This role combines manufacturing logistics/material-flow experience with structured continuous-improvement methodology. The successful candidate will be trained in Cornerstone's pillar methodology and will lead implementation of tools designed to reduce shortages, WIP, material handling, travel, expediting and schedule disruption. Candidates are not expected to have prior expertise in every Material Flow pillar tool. Strong manufacturing logistics/supply-chain knowledge, analytical capability and experience improving material movement and availability are most important.

Requirements

Experience in manufacturing logistics, materials, supply chain, warehouse operations, production control or manufacturing operations.
Demonstrated experience solving material-availability or process-flow problems.
Exposure to Lean, continuous improvement or structured problem-solving methods.
Strong analytical and organizational capability.
Ability to work cross-functionally and lead change on the manufacturing floor.

Nice To Haves

Experience with one or more of: PFEP, Kanban, supermarkets, FIFO, milk runs/material routes, point-of-use delivery, VSM or inventory optimization.
Experience in a high-volume manufacturing environment.
Familiarity with production scheduling or leveling concepts.

Responsibilities

Lead the Material Flow pillar implementation and associated Master Plan.
Establish baseline losses related to shortages, WIP, inventory, material touches, travel, lead time, overtime and delivery performance.
Develop and maintain a Plan for Every Part (PFEP).
Map current material flow using tools such as Value Stream Mapping, process mapping and spaghetti/route analysis.
Analyze material shortages and interruptions using Pareto and structured problem solving.
Evaluate and improve material feeding strategies.
Develop and implement appropriate FIFO, pull, supermarket, Kanban/two-bin and controlled-buffer systems.
Improve point-of-use material presentation and line-side inventory.
Establish standard material-delivery routes, replenishment frequencies and route timing.
Determine appropriate replenishment quantities and inventory levels.
Improve receiving, warehouse, staging and line-side material standards.
Partner with Planning, Purchasing, Operations, Engineering, Quality and suppliers to improve material availability and flow.
Support production-leveling activities using concepts including takt, pitch, capacity, buffers and Heijunka.
Integrate applicable Scheduling/Kaizen improvements into the Material Flow plan.
Lead Activity Board reviews and maintain clear ownership and closure of actions.
Train and coach employees on new material-flow standards.
Measure results and ensure new systems are sustained.