Director of Continuous Improvement

ROLE PURPOSE

The Director of Continuous Improvement is responsible for leading the development, implementation, and sustainability of the Continuous Improvement and Manufacturing Excellence strategy across the organization’s U.S. manufacturing operations.

This role partners closely with Operations, Engineering, FSQA, Supply Chain, Finance, HR, and Commercial leadership to identify opportunities, eliminate waste, improve process capability, increase labor and equipment efficiency, and deliver sustainable improvements in safety, quality, delivery, cost, and people performance.

The Director of Continuous Improvement will establish and deploy a consistent Continuous Improvement operating system utilizing Lean Manufacturing, Six Sigma, TPM, problem-solving, and other operational excellence methodologies. This leader will work directly with site leadership teams to translate business priorities into actionable improvement plans and ensure initiatives deliver measurable operational and financial results.

The ideal candidate is a hands-on transformation leader who can move seamlessly between strategy and practical implementation. This individual will be equally comfortable facilitating executive-level strategy discussions, coaching plant leadership teams, and working directly on the manufacturing floor to identify root causes and implement sustainable solutions.

KEY ACCOUNTABILITIES

• Develop and lead the Continuous Improvement and Manufacturing Excellence strategy across U.S. manufacturing operations, ensuring alignment with overall business objectives and growth plans.
• Establish a clear Continuous Improvement framework centered around five key operational imperatives:
• Safety: Improve processes and eliminate operational risks that contribute to injuries, unsafe conditions, and ergonomic concerns.
• Quality: Reduce defects, rework, waste, and process variation while supporting a right-first-time culture.
• Delivery: Improve flow, throughput, schedule attainment, capacity utilization, and customer service performance.
• Cost: Deliver measurable productivity and cost improvements through labor optimization, waste reduction, yield improvement, process efficiency, and Continuous Improvement initiatives.
• People: Build Continuous Improvement capability throughout the organization by developing leaders, engaging employees, and creating ownership for sustainable improvement.
• Partner with site and functional leadership to develop short- and long-term Continuous Improvement roadmaps based on business priorities, operational performance, capacity requirements, and growth objectives.
• Identify, prioritize, and lead high-impact improvement initiatives focused on OEE, labor efficiency, yield, waste, changeover reduction, downtime, throughput, service, capacity, and overall manufacturing cost.
• Establish measurable financial and operational targets for Continuous Improvement initiatives and partner with Finance to validate savings, productivity gains, cost avoidance, and overall business impact.
• Develop and implement standardized Lean Manufacturing practices, tools, and routines across manufacturing locations.
• Lead Value Stream Mapping, Kaizen events, 5S, Standard Work, SMED, visual management, root-cause analysis, problem-solving, and other structured improvement activities.
• Champion Total Productive Maintenance (TPM) principles in partnership with Engineering, Maintenance, and Operations to improve equipment reliability, reduce unplanned downtime, and increase asset utilization.
• Develop and implement Daily Management Systems and performance routines that provide clear visibility to operational performance, gaps, actions, and accountability.
• Establish governance and tracking processes for Continuous Improvement projects, including project prioritization, ownership, milestones, benefits realization, and sustainability.
• Analyze operational data and performance trends to identify opportunities, determine root causes, prioritize resources, and drive fact-based decision-making.
• Partner with Operations and Engineering to evaluate manufacturing capacity, labor requirements, equipment capability, automation opportunities, process design, and capital investment needs.
• Ensure Continuous Improvement principles are incorporated into new equipment, new product introductions, facility changes, capacity expansion, and other strategic business initiatives.
• Facilitate cross-functional problem-solving efforts involving Operations, Engineering, FSQA, Supply Chain, Finance, HR, Commercial, and other business functions.
• Build Continuous Improvement capability throughout the organization by developing training programs, coaching leaders, and creating practical tools that enable employees at all levels to identify and solve problems.
• Coach and mentor site leaders, managers, supervisors, and frontline employees on Lean leadership behaviors, structured problem-solving, and Continuous Improvement methodologies.
• Develop internal Continuous Improvement champions and establish a sustainable network of employees capable of leading improvement initiatives within their respective functions and sites.
• Drive standardization and replication of best practices across manufacturing locations to ensure successful improvements are leveraged throughout the broader organization.
• Create and maintain Continuous Improvement scorecards and dashboards to communicate project status, operational improvements, financial benefits, and overall program effectiveness to senior leadership.
• Support the development of annual operating plans by identifying productivity opportunities and establishing a pipeline of Continuous Improvement initiatives aligned with financial and operational targets.
• Serve as a change leader who challenges existing processes constructively while building strong partnerships and organizational commitment to improvement.
• Promote a culture where employees are encouraged to identify problems, challenge inefficiencies, recommend solutions, and actively participate in improving the business.
• Ensure all Continuous Improvement activities support and strengthen food safety, quality, employee safety, regulatory compliance, and customer requirements.
• Act as a coach, mentor, and role model for the organization’s values while maintaining the highest standards of ethics, accountability, and corporate governance.

EDUCATION and/or EXPERIENCE

• Bachelor’s degree in Engineering, Operations Management, Business, Supply Chain, Manufacturing, or related field required; equivalent combination of education and significant relevant experience may be considered.
• Minimum 8–10 years of progressive manufacturing, operations, engineering, or Continuous Improvement experience, with significant experience in food manufacturing or another high-volume manufacturing environment.
• Minimum 5 years of experience leading Continuous Improvement, Operational Excellence, Lean Manufacturing, or Manufacturing Excellence initiatives.
• Demonstrated track record of delivering measurable improvements in productivity, labor efficiency, OEE, yield, waste, throughput, equipment reliability, and/or manufacturing cost.
• Expert knowledge of Lean Manufacturing principles and Continuous Improvement methodologies, including Value Stream Mapping, Kaizen, 5S, Standard Work, SMED, visual management, root-cause analysis, and structured problem-solving.
• Strong knowledge of Six Sigma methodologies and statistical problem-solving techniques.
• Experience implementing or supporting Total Productive Maintenance (TPM) and equipment reliability improvement programs.
• Demonstrated ability to translate Continuous Improvement initiatives into measurable financial results and partner effectively with Finance to validate benefits.
• Strong analytical skills with the ability to interpret manufacturing data, identify trends, determine root causes, and develop practical solutions.
• Demonstrated experience leading organizational change and influencing leaders and teams without relying solely on direct authority.
• Strong facilitation, coaching, communication, and presentation skills with the ability to work effectively from the production floor through executive leadership.
• Experience developing Continuous Improvement capability through training, coaching, mentoring, and leadership development.
• Working knowledge of FDA, USDA, OSHA, GMP, HACCP, and applicable food manufacturing requirements preferred.
• Lean Six Sigma Black Belt certification strongly preferred.
• Location: Charlotte, NC preferred with Carson, CA and San Antonio as potential options
• Travel 30-50%