Continuous Improvement Manager - Malibu Boats

Summary The Continuous Improvement (CI) Site/Brand Lead is responsible for driving operational excellence across assigned MBI manufacturing operations, supporting the end‑to‑end production of premium boats and marine components. The role partners closely with plant and MBI leadership to enhance performance in hull fabrication, assembly, upholstery, rigging, and finishing while preserving the craftsmanship and brand quality MBI is known for. A core accountability of this role is the reduction of Cost of Poor Quality (COPQ) through disciplined problem‑solving, defect elimination, and process control. Key Responsibilities Own plant‑wide COPQ reduction strategy, including: Baseline accuracy Internal failures (scrap, rework, repair hours) External failures (warranty, dealer claims, field issues) Extended appraisal costs (inspection inefficiencies) Align with MBI Quality initiatives by co‑establishing brand/site baseline COPQ metrics and driving year‑over‑year reduction targets. Lead structured problem‑solving activities using A3 thinking, Root Cause Analysis (RCA), and 8D / DMAIC methodologies. Facilitate cross‑functional problem‑solving workshops, coaching, and training focused on inspection, rework, gelcoat and cosmetic defects, upholstery rework, and electrical and functional system failures. Ensure permanent corrective actions with validation, standardization, and follow‑up audits. Build capability across teams to solve problems at the root cause, not symptoms. Create transparency through COPQ dashboards and integrate data into daily management. Operational Excellence in Premium Boat Manufacturing Lead continuous improvement initiatives across key brand/site production processes: Parts and component assembly Fiberglass hull/deck layup Upholstery and interior finishing Rigging (electrical, ballast, surf systems) Final assembly, detailing, and water testing Improve flow and reduce bottlenecks in large‑product, station‑based assembly. Optimize takt alignment and line balancing in high‑mix production. Lean Deployment (Craftsmanship + Efficiency) Implement Lean tools while protecting Malibu’s premium quality standards: Standard Work with built‑in quality controls Visual Management for production and quality performance 5S in high‑visibility, finish‑critical areas Layered Process Audits (LPA) Optimal setup and controls leading to defect and COPQ reduction Target waste reduction in resin and composite material usage, rework loops and repair stations, and labor inefficiencies driven by variation. Quality & Brand Protection Partner with MBI Quality to protect the premium brand reputation. Improve first‑pass yield (FPY), reduce defects per unit (DPU), and reduce defect escape rates. Drive mistake‑proofing (poka‑yoke) in critical systems affecting safety, performance, and customer‑visible quality. Connect plant metrics directly to dealer and customer satisfaction. Customer & Dealer Experience Integration Translate dealer feedback and warranty trends into actionable improvement plans. Close the loop between field issues and plant corrective actions. Prioritize improvements that enhance the on‑water customer experience. Performance Management & Visual Systems Establish plant‑wide SQDC and COPQ visual management systems. Track and drive key KPIs: COPQ as % of sales Rework hours per boat FPY and/or DPU Warranty cost per unit Throughput and on‑time delivery Lead daily Gemba and tiered accountability meetings. Production Scaling Support ramp‑up/down aligned to demand cycles. Improve workforce flexibility via cross‑training and standard work. Maintain quality discipline during high‑volume peak periods. Culture & Capability Building Support growth of problem‑solving capability at all levels of the organization. Coach supervisors and team leaders on structured CI and defect elimination. Drive accountability for a “build it right the first time” mindset. Increase employee engagement in kaizen and continuous improvement. Project Leadership & Execution Lead a pipeline of CI projects with measurable impact on COPQ and operational performance. Partner with Engineering, Production, Quality, and Supply Chain. Ensure sustainability through standard work, audits, and leader standard work. Qualifications Education & Experience Bachelor’s degree in engineering, manufacturing, operations, or related field. 8–10+ years of experience in manufacturing, continuous improvement, and/or operational excellence activities. Strong experience driving quality improvement and COPQ reduction. Demonstrated performance in marine, automotive, RV, or other high‑mix assembly environments preferred. Strong project management, organizational, and analytical skills. Excellent communication, training, and facilitation abilities. Experience with data analysis, modern QMS tools, and advanced manufacturing concepts. Skills & Knowledge Deep expertise in root‑cause problem solving (A3, 8D, DMAIC), COPQ analysis, and budgetary impact modeling. Lean manufacturing principles. Experience with industry materials and finishing processes strongly preferred. Lean Six Sigma certification (Green/Black Belt) preferred. Strong leadership, team building, group facilitation, and change management skills. Key Competencies Accountability, dependability, adaptability, and flexibility. Coaching and mentoring. Creative, innovative thinker. Good decision making and judgment. Ethics, integrity, and honesty. Willingness to learn. Relentless focus on defect elimination and root cause resolution. Passion for craftsmanship and premium product quality. Data‑driven decision‑making with strong shop‑floor instincts. Ability to lead in high‑variation, custom manufacturing. Strong cross‑functional leadership and influence. Systems thinking and standardization. Project management and execution. Training and capability development. Attention to detail and documentation rigor. Change management. Success Metrics Activity‑based transformational results. Year‑over‑year reduction in COPQ (% of revenue). Reduction in rework hours and defect rates. Improved first‑pass yield and DPU across all production stages. Decrease in warranty claims and field failures. Increased throughput without quality degradation. Support improvement of on‑time delivery performance. Sustained cost savings tied to defect elimination. Physical Demands Continuous/C = 67‑100%, Frequent/F = 33‑66%, Occasional/O = 33%, None/N. Sits hours, stands hours, walks hours, drives hours. Employee lifts and/or carries (maximum 50 lbs frequently 20 lbs occasionally 35 lbs). Employee uses hands for repetitive activities: simple grasping, pushing/pulling, fine manipulation. Employee uses feet for repetitive activities: right and left. Bending at waist, squatting, climbing ladders, stairs, kneeling on ground, reaching above shoulder. Work Environment Hands‑on role with significant presence on the manufacturing floor. Exposure to various settings – fiberglass, finishing, and assembly operations. Fast‑paced, focused production environment. Typical 10‑hour workdays based on facility. Typical 4‑ or 5‑day work week schedule based on facility and schedule loading. Overtime is occasional to frequent based on a number of factors. Required to work indoors and outdoors, year‑round and in all weather conditions. May be required to work during production shutdowns or other “off‑schedule” periods to conduct special activities. Safety glasses required while in production areas. #J-18808-Ljbffr Malibu Boats