Director, Process Excellence

Role Overview

• Develop and execute the engineering driven, lean focused roadmap that delivers higher quality, higher productivity, lower cost, and safer workplaces
• Lead the design, qualification (IQ/OQ/PQ) and scale‑up of manufacturing processes, equipment, fixtures, and tooling for new products and product revisions
• Own the NPI hand‑over from R&D to the shop floor, ensuring cost, cycle‑time, and yield targets are met
• Drive retrofits, automation upgrades, and line redesigns that improve OEE and reduce change‑over time (SMED)
• Create and maintain robust work instructions, SOPs, and process specifications that are the “single source of truth” for production
• Perform takt‑time analysis, line balancing, and capacity modeling to meet forecast demand while minimizing labor and equipment bottlenecks
• Design/optimize plant layouts, cellular manufacturing cells, and material flow (value‑stream mapping) for maximum efficiency and minimal handling
• Use discrete‑event simulation, digital twin tools, and data analytics to evaluate “what‑if” scenarios before physical changes are made
• Conduct time‑studies, method‑studies, and ergonomic assessments to set standard labor times and reduce fatigue
• Build and sustain a plant‑wide lean system (5S, visual management, pull systems, Kanban, JIT) tailored to each operation
• Lead a certified Black‑Belt/Green‑Belt program, prioritize high‑impact projects, and ensure statistically‑validated results (DEFECT‑Reduction, Cycle‑Time, Cost)
• Translate corporate strategic goals into annual/quarterly lean objectives; cascade metrics down to the shop floor
• Conduct daily Gemba walks, coaching frontline supervisors on problem‑solving (A3, 5‑Why) and rapid improvement cycles
• Recruit, develop, and retain a high‑performing ME/IE/Lean team (engineers, analysts, facilitators)
• Mentor plant leaders and front‑line teams in lean thinking, data‑driven decision making, and change management
• Create a “continuous‑improvement as a habit” culture measured by participation rates and sustained gains
• Define the KPI set for ME, IE, and Lean (OEE, SCRAP, First‑Pass Yield, Labor Hours per Unit, Change‑over Time)
• Integrate MES/ERP data streams into real‑time dashboards; ensure data integrity for decision making
• Champion the use of advanced analytics (statistical process control, predictive maintenance, AI) to pre‑empt losses
• Build business cases (ROI, payback) for all engineering and lean projects; track actual savings vs. target
• Partner with Finance to embed process costs into product costing and margin analysis
• Embed EHS and Quality requirements (ISO/TS, GMP, IATF) into every process design and lean activity
• Conduct risk assessments (PFMEA, Process Hazard Analysis) and drive corrective actions promptly

Requirements

• Bachelor's degree with 10 plus years of relevant experience OR Master's degree with 8 plus years of relevant experience
• 10 plus years progressive experience in manufacturing/industrial engineering
• At least 5 years in a leadership role focused on lean/continuous improvement
• Certified Lean Practitioner
• Proven ability to lead cross‑functional, matrixed teams and to influence senior leadership without direct authority
• Proven ability to build and maintain high performing teams
• Proven ability to take ownership and be accountable with an “owners” mindset
• Strong business/financial acumen, keen organizational skills, and excellent problem-solving ability
• Ability to obtain and maintain a security clearance up to Top Secret

Tech Stack

• ERP
• TypeScript

Benefits

• Health insurance coverage
• Life and disability insurance
• Savings plan
• Company paid holidays
• Paid time off (PTO) for vacation and/or personal business