Regional Lean and Six Sigma Manager

Ford•Dearborn, MI

About The Position

Established and active employee resource groups Strategic Leadership: Set the strategic direction for Lean and Six Sigma initiatives, collaborating with plant leadership and various departments (operations, engineering, quality, etc.), and identifying innovative technologies and methods to improve asset reliability and operational efficiency. Kaizen Leadership: Take a lead role in coordinating and executing Kaizen events at critical plants in accordance with strategic objectives for the organization. Team Management: Lead and develop a team of Lean Coaches to execute FPS, Lean, and Six Sigma initiatives at the plant level, including managing performance, setting goals, and fostering a collaborative work environment. Process Improvement & Training: Develop and implement Lean and Six Sigma processes, including Value Stream Mapping, DMAIC methodologies, root cause analysis (RCA), preventative/predictive maintenance strategies, and key performance indicator (KPI) tracking. Coordinate training sessions on FPS Continuous Improvement, DMAIC, CI Specialist, Problem Solving, ERC, 6-Sigma Green/Black Belt, and other Lean tools. Technology Implementation: Drive the adoption of predictive maintenance technologies and data infrastructure (CMMS, analytics platforms) to support reliability and continuous improvement efforts. Financial Management: Interact with budgeting processes, justify capital expenditures related to asset reinvestment and continuous improvement projects, and optimize maintenance/operational costs while maximizing asset lifespan and performance. Cross-Functional Collaboration: Effectively collaborate with various stakeholders, including Directors of Manufacturing, Plant Managers, Plant Lean and Six Sigma Team Managers, Maintenance Managers, Global Manufacturing Engineering, Skilled Trades, and others across various business units. Culture & Engagement: Create a sense of community and culture of belonging by engaging in Gemba walks, collaborative problem-solving, coaching, and visibly celebrating team accomplishments. Role model integrity and servant leadership. Travel to support operating facilities, workshops, industry benchmarking and training sessions as needed (approx 80%) Established and active employee resource groups Education: Associate's degree or equivalent experience in an engineering or technical field 4+ years of progressive responsibilities and experience in operations leadership Deep understanding of reliability engineering principles, tools, and methodologies (FMEA, RCFA, RCM, PMO), Lean Manufacturing principles (VSM, Kaizen, 5S), and Six Sigma methodologies (DMAIC). Experience with predictive maintenance technologies and strong analytical skills for data analysis and interpretation. Proficiency with IBM Maximo is necessary as all maintenance activities are to be documented there. Extensive experience in high-volume, complex, manufacturing environments Experience successfully leading kaizen workshop in complex manufacturing systems Demonstrated track record of building trust and rapport with employees and creating positive and healthy cultures. Excellent leadership skills with demonstrated ability to resolve diverse problems Strong problem solver who can lead effectively under pressure and crisis manage when necessary Aspiration for continued career growth and new challenges Education: Bachelor's degree in an engineering or technical field Certifications: Six Sigma Black Belt or Master Black Belt certification. 5+ years of proven ability to lead and mentor teams, manage multiple complex projects, and effectively communicate with all levels of the organization. Experience in a unionized environment is a significant advantage. Operational experience leading manufacturing processes across multiple areas (body, paint, final assembly, etc.) Experience working in a fast-paced unionized manufacturing environment

Requirements

Associate's degree or equivalent experience in an engineering or technical field
4+ years of progressive responsibilities and experience in operations leadership
Deep understanding of reliability engineering principles, tools, and methodologies (FMEA, RCFA, RCM, PMO), Lean Manufacturing principles (VSM, Kaizen, 5S), and Six Sigma methodologies (DMAIC)
Experience with predictive maintenance technologies and strong analytical skills for data analysis and interpretation
Proficiency with IBM Maximo is necessary as all maintenance activities are to be documented there
Extensive experience in high-volume, complex, manufacturing environments
Experience successfully leading kaizen workshop in complex manufacturing systems
Demonstrated track record of building trust and rapport with employees and creating positive and healthy cultures
Excellent leadership skills with demonstrated ability to resolve diverse problems
Strong problem solver who can lead effectively under pressure and crisis manage when necessary
Aspiration for continued career growth and new challenges
Bachelor's degree in an engineering or technical field
Six Sigma Black Belt or Master Black Belt certification
5+ years of proven ability to lead and mentor teams, manage multiple complex projects, and effectively communicate with all levels of the organization

Nice To Haves

Experience in a unionized environment is a significant advantage
Operational experience leading manufacturing processes across multiple areas (body, paint, final assembly, etc.)
Experience working in a fast-paced unionized manufacturing environment

Responsibilities

Set the strategic direction for Lean and Six Sigma initiatives
Collaborate with plant leadership and various departments (operations, engineering, quality, etc.)
Identify innovative technologies and methods to improve asset reliability and operational efficiency
Coordinate and execute Kaizen events at critical plants in accordance with strategic objectives for the organization
Lead and develop a team of Lean Coaches to execute FPS, Lean, and Six Sigma initiatives at the plant level
Manage performance, setting goals, and fostering a collaborative work environment
Develop and implement Lean and Six Sigma processes, including Value Stream Mapping, DMAIC methodologies, root cause analysis (RCA), preventative/predictive maintenance strategies, and key performance indicator (KPI) tracking
Coordinate training sessions on FPS Continuous Improvement, DMAIC, CI Specialist, Problem Solving, ERC, 6-Sigma Green/Black Belt, and other Lean tools
Drive the adoption of predictive maintenance technologies and data infrastructure (CMMS, analytics platforms) to support reliability and continuous improvement efforts
Interact with budgeting processes
Justify capital expenditures related to asset reinvestment and continuous improvement projects
Optimize maintenance/operational costs while maximizing asset lifespan and performance
Effectively collaborate with various stakeholders, including Directors of Manufacturing, Plant Managers, Plant Lean and Six Sigma Team Managers, Maintenance Managers, Global Manufacturing Engineering, Skilled Trades, and others across various business units
Create a sense of community and culture of belonging by engaging in Gemba walks, collaborative problem-solving, coaching, and visibly celebrating team accomplishments
Role model integrity and servant leadership
Travel to support operating facilities, workshops, industry benchmarking and training sessions as needed (approx 80%)