Purpose
Lead the implementation of Lean Six Sigma methodologies to optimize manufacturing processes, reduce waste, improve product quality, and enhance overall efficiency in a high-mix, low-volume ESP manufacturing environment encompassing both engineer-to-order (ETO) and make-to-order (MTO) configurations.
Key Responsibilities
- Prepare comprehensive improvement plans with detailed process maps, project specifications, and cost-benefit estimates for Lean Six Sigma initiatives across all 18 product lines.
- Contribute to new business initiatives and projects, reviewing and communicating the impact on Lean activities and operational excellence goals.
- Present analysis results and project solutions to technical leads, senior leaders, and clients, demonstrating measurable improvements in manufacturing performance.
- Develop a robust continuous improvement strategy in partnership with the Management Team and key business stakeholders, specifically addressing HMLV (High Mix, Low Volume) manufacturing challenges.
- Implement and support cultural change across the organization, driving business improvement through Lean Six Sigma methodologies.
- Develop, deliver, and support delivery of business improvement change initiatives tailored to manual manufacturing processes and diverse workforce requirements.
- Develop and contribute towards improvement standards in line with Lean Six Sigma best practices, specifically adapted for ESP manufacturing requirements.
- Undertake comprehensive business process analysis and statistical analysis for improvement initiatives, supporting wider organizational change.
- Lead, define, and develop continuous improvement activities designed to improve performance, including planning and executing Kaizen events, value stream mapping sessions, and SMED workshops.
- Perform systematic root cause analysis using Six Sigma tools (fishbone diagrams, 5-Why analysis, statistical analysis) to resolve complex manufacturing problems.
- Conduct detailed value stream mapping exercises across ETO and MTO production systems to identify waste sources and improvement opportunities.
- Implement Lean tools including 5S, Standard Work, Visual Management, Kanban systems, and error-proofing techniques specifically designed for manual manufacturing processes.
- Apply Six Sigma methodologies (DMAIC, DMADV) to reduce process variation, improve first-pass yield targets, and enhance overall product quality.
- Establish and monitor key performance indicators (KPIs) to track effectiveness of improvement initiatives and ensure sustainable results.
Qualifications & Skills:
- Bachelor's degree in industrial engineering, Manufacturing Engineering, Mechanical Engineering, or related technical field.
- Certified Lean Six Sigma Green Belt certification (minimum requirement).
- Lean Six Sigma Black Belt certification is highly preferred.
- Additional certifications in project management (PMP) or quality management (ASQ) are advantageous.
- Minimum 5-7 years of experience in manufacturing environment with significant continuous improvement focus.
- Previous Oil and Gas equipment manufacturing experience is strongly preferred.
- Proven experience in high-mix, low-volume (HMLV) manufacturing setting is essential.
- Experience with engineer-to-order (ETO) and make-to-order (MTO) production systems is highly desirable.
- Comprehensive knowledge of Lean Six Sigma methodologies and tools including VSM, 5S, Kaizen, Standard Work, SMED, DMAIC, and DMADV.
- Working knowledge of MS Office suite and ERP/MRP systems.
- Proficiency in statistical analysis software (Minitab, JMP, or equivalent).
- Strong analytical and problem-solving skills with experience in process mapping and analysis.
- Excellent reporting and documentation skills.
- Demonstrated experience in leading cross-functional teams and driving organizational change.
