Continuous Improvement Manager
Cornerstone Building Brands, headquartered in Cary, North Carolina, is the largest manufacturer of external building products in North America with over $6 billion in annual revenue and an expansive North American footprint that includes almost 20,000 employees, operating in +70 manufacturing facilities, supported by a network of +80 distribution and branch office facilities. We have a broad product offering with a well-regarded brand portfolio including the #1 position in windows, vinyl siding, metal accessories, and metal roofing and wall systems. We believe every building we create, and every part of that building, positively contributes to communities where people live, work and play.
The Continuous Improvement Manager will lead bold change through the Lean Manufacturing initiatives at the site to ensure continuous, systemic, and sustainable elimination of waste through developing a fully engaged culture of continuous improvement (zero waste mindset), execution of Kaizen Events linked to the site Vision and annual Strategy Deployment and building of foundational capability for long term sustainment. Create a vision that directs change efforts at the site and develops strategies / action plans to achieve the vision. Eliminate barriers to change and modify systems / processes as required in support of Lean and Consumption Driven Supply principles (on demand, defect free, one by one, at lowest cost).
Responsibilities :
Lead Site Guiding Coalition
- Be the change agent drive and accelerate change in culture, attitude, and capability
- Annual planning of Kaizen Event activities to support Site Strategy Deployment based on Value Stream Mapping and Waste Analysis
- Quarterly priority setting of Kaizen Events to deliver step change in results (60 90-day outlook) at the target pace for the site
- Approval of Kaizen events & close-out and sustainment plans
- Ensure Lean tool capability is developed across the site
- Drive employee engagement by ensuring a high percentage of new members on Kaizen Events
- Approval of standards, systems, and processes to support sustainable execution
- Approval of site standards as related to Lean methodologies and implementation
- Develop, modify, and improve standard processes to continuously improve efficiency of Coalition related to the above responsibilities
- Instill a standard, disciplined, rigorous, process focused approach to problem solving across the organization
- Actively participate in the CI Steering Committee to share, develop, and deploy Business Unit standards for Lean tools, principles, and methodologies as well as standard business processes
Daily / Active Waste Elimination Coaching
Participate in Accountability Meetings daily with Operations Manager or Production Managers to highlight opportunities for continuous improvement in Lean principles / tools and adherence to production system standardsParticipate in weekly (or periodic based on site) Production Department meetings to support development of corrective actions and coach problem solving methodologyParticipate in periodic Functional Department meetings to identify gaps / issues which need resolution, assist in the prioritization of work processes, and support in the development of corrective actionsOutside of the Production Departments or Functional Department meetings (monthly minimum), coach structure and linkage of the Business Boards to ensure proper cascade of measures, targets, and actions from Leadership to shopfloorIdentify and lead training in accordance with the needs defined by the Guiding Coalition, Site Strategy Deployment, and personal observation (daily coaching and walk throughs). Ensure proper understanding of these tools / techniques and ownership of deployment.Kaizen Event Facilitation
Drive the site to model a Learn by Doing approachOrganize / facilitate Kaizen Event-based and specific tool training for all monthly Kaizen Event teamsCoordinate Preparation, Execution, and Follow-Up stages of the Kaizen Event process through weekly interaction with Leaders / Co-Leaders to ensure team is on pace with the guidelines / expectations of Kaizen Methodology.For Kaizen Teams that go beyond the desired 30-day close-out window, work with Team Leaders / Co-Leaders and Business Owner to close all open follow-up items and execute countermeasures to close gaps against desired deliverables / resultsLean Tool Capability
Develop personal mastery in the Lean principles and tools to allow broad facilitation (Kaizen events, lean workshops, and daily coaching) in Production Departments and Functions. This shall include a mastery of training modules such as Waste Elimination, 5S, Root Cause Problem Solving, Standard Work, SMED, PM, Plan-Do-Check-Act, and other lean tolls defined in our production system.Coordinate Kaizen event Training process to ensure the site has broad base capability in all primary Lean tools to be self-sufficient for monthly and on-demand training requirementsLead training sessions and Kaizen Events within the site or within other CBB facilities as required.Reapplication / Benchmarking
Develop and facilitate Lean Manufacturing Annual Plans within the site to ensure best practices are shared and reapplied efficiently to accelerate resultsActively participate in the CBB CI Steering Committee meetings share successful improvements with the network for potential reapplication to accelerate Company results and be open to learning from other site to reapply successful, sustained improvementsActively participate in Benchmarking visits and audits as required at CBB sites. The expected output from any such visit is a potential list of potential reapplications to be reviewed and inserted into the Idea Sharing read Across.Identify industries / companies / sites within the same geographic region to conduct external benchmarking based on performance and Lean journey progressStrategy Deployment
Provide support to the CI Steering Committee in their implementation of actions, sharing his knowledge and practical experience in handling lean tools as requiredEnsure process confirmation through a relevant Go-Look-See process, to understand, support / coach, and challenge associates toward the achievement of expected business resultsIn conjunction with the Plant Manager, lead the Site Leadership Team in the development of the Site Cost Take Out Roadmap linked to the Company Strategies and ObjectivesIn conjunction with the Plant Manager, lead / coordinate the Site Leadership Team in development of annual plan Strategy Action Plans to achieve the Company goalsCoordinate the monthly Strategy Deployment process including normal updates, gap analysis, and countermeasure developmentConduct periodic reviews and audits of the Site, Production Department, and Functional Department WIT Boards to ensure ongoing alignment to the annual objectives, linked KPIs, site initiatives, and site standardsManage the preparation of daily reports.Facilitate quarterly projects with Supervisors and Group Leads to ensure development, presentation and completion of improvements following the Paris documented processContinue to develop, certify, and train on TWI (Training with Industry) principlesCoordinate with Human Resources on Onboarding, Mentorship and Skill Matrix applicationsResponsible for personal safety as well as the promotion of, involvement in, and enforcement of all Environmental, Health, and Safety (EHS) efforts at this facility. This includes complying with all EHS policies or regulations set forth by Simonton and / or various governmental agencies.
Provides strong leadership skills in a one-on-one environment and in a team atmosphere.
Qualifications
BA / BS (4-year technical or business) degree preferable4 6 years of Manufacturing Operations experienceGreenbelt Certification required Black Belt PreferredPrevious Lean experience a positive for internal candidates and required for external candidates, High school graduate with some college.Extensive experience leading and facilitating formal Kaizen eventsAble to build successful teams and guide others in accomplishing work objectivesStrong analytical and problem-solving capabilitiesSeeks and uses 'customer' feedback to improve effectiveness of Lean group and deploymentEncourages open discussion and dialogue within and between FunctionsWell-developed decision-making skillsExcellent computer and analytical skillsExcellent verbal, written and interpersonal communication skillsLead and Manage by InfluenceIndividual and Team CoachingExtremely Process FocusedExcellent self-motivation and attitude toward their workHigh degree of maturity and professionalismWhy work for Cornerstone Building Brands?
Our teams are at the heart