Senior Material Handling & Lean Operations Expert

Job Description Job Description Job Title:
Location: California (client site – on-site / hybrid flexibility depending on project phase)
Type: Contracted (project-based, typically 6–12 months, with strong potential for extension)
Compensation: Competitive, commensurate with experience
Overview VDS Consulting Group is seeking a proven Senior Lean Practitioner and Material Handling Expert to drive transformational improvements for a high-volume, low-mix equipment manufacturer in California. In this hands-on consulting role, you will partner directly with plant leadership and operations teams to optimize material flow, eliminate waste, and deliver rapid, measurable gains in productivity, inventory turns, and on-time delivery.
This is a high-impact opportunity for a lean expert who thrives in repetitive manufacturing environments. You will design and implement best-in-class material handling systems that support high-volume production with minimal product variation—think standardized processes, point-of-use delivery, and flow optimization that directly contribute to EBITDA uplift and operational excellence.
Key Responsibilities Lead comprehensive material-handling assessments and redesign material-flow strategies (PFEP, supermarkets, kanban, milk-run/tugger systems, automated guided vehicles, and point-of-use storage) tailored to high-volume, low-mix production.
Apply deep lean expertise to identify and eliminate waste in internal logistics, line-side replenishment, and warehouse-to-line movement while maintaining or improving safety and quality standards.
Develop and execute value-creation playbooks focused on material handling, including layout optimization, visual management, standard work for material handlers, and integration with production scheduling.
Coach and mentor client teams on lean principles, change management, and sustained continuous improvement (Kaizen events, daily management systems, and performance dashboards).
Collaborate with cross-functional stakeholders (operations, engineering, supply chain, and finance) to quantify improvements, track KPIs (OEE, inventory turns, labor efficiency, dock-to-line time), and deliver 100-day action plans with clear ROI.
Support broader portfolio operations initiatives, including supply-chain synchronization and cost-reduction programs tied to material handling excellence.
Qualifications & Experience Minimum 8 years of hands-on lean practitioner experience in manufacturing operations, with a strong emphasis on material handling and logistics optimization.
Proven track record in high-volume, low-mix environments (equipment manufacturing, automotive components, appliances, or similar repetitive production settings is highly preferred).
Deep expertise in lean tools and methodologies: PFEP, value-stream mapping, Kanban, 5S, SMED, pull systems, and material-flow simulation.
Demonstrated success delivering measurable results (e.g., 20–40% reduction in material-handling labor, 30%+ improvement in inventory turns, or significant OEE gains).
Prior experience in private-equity-backed or portfolio companies is a strong plus.
Excellent communication, influence, and project-management skills; able to operate independently and drive change in a fast-paced plant environment.
Bachelor’s degree in Industrial Engineering, Supply Chain, Operations, or related field required; Lean/Six Sigma Black Belt or equivalent certification strongly preferred.
Willingness to be on-site in California for the duration of the engagement.
If you are a results-oriented lean expert who has transformed material handling in high-volume manufacturing settings and are ready to deliver tangible value for a PE-backed equipment manufacturer, we want to hear from you.
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