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Consultant - Lean Manufacturing (Ann Arbor, MI)

Projected Start Date: March 1, 2016


This position is for a Lean Manufacturing consultant. The Lean Manufacturing consultant will work with diverse clients ranging from small and medium size enterprises to large Fortune 100 enterprises to deliver lean manufacturing improvements. Working in a team environment, the individual in this role will develop, analyze and optimize clients’ processes.  Engagements are usually longer in duration and allows consultant to oversee the implementation of improvement recommendations.  The primary role of the consultant will be to assess existing manufacturing facilities and processes, develop improvement plans, and assist in developing requirements for future manufacturing facility growth and expansion. 

Job Responsibilities:


In general, the Lean Manufacturing consultant will perform the following job responsibilities in addition to others as required for each project:


  • Review of existing material flow against all components involved, including material flow mapping and material flow analysis for process improvement.

  • Utilize manufacturing metrics to create value in the material flow analysis.  

  • Review material display for work station layouts.

  • Review current methods of material handling.

  • Review staffing requirements for material flow scopes.

  • Perform lean assessments of plan operations and organization.

  • Develop value stream maps and flow diagrams.

  • Identify opportunities for process improvement.

  • Monitor existing manufacturing processes to continuously improve processes, efficiency and throughput, quality, setup reduction, and cost reduction activities.

  • Design, develop, test, and/or source and implement various tools, cutters, machinery, & equipment for recommended lean manufacturing methods.

  • Provide solutions to problems using both creative processes and analytical methods.

  • Ability to separate the root-cause from intervening symptoms.

  • Make informed decisions based upon limited data.

  • Assure that a holistic organizational approach (Design, Manufacturing Engineering, Manufacturing, Purchasing, Scheduling, Finance, Sales, etc.) to improvements is used to eliminate improvement activities producing contradicting priorities, work, initiatives, and/or policies.

  • Develop and implement documentation of manufacturing work instructions, process flow diagrams, and PFMEA.

  • Interface with customers and implement corrective actions to resolve quality concerns and process related issues.

General Consultant Qualifications:


Qualified candidates for Lean & Continuous Improvement Consultant positions will have the following qualifications:


  • Ability to work independently in thoroughly analyzing data and influencing leadership to make decisions and to take actions.

  • Ability to work with and influence all levels within the organization.

  • Must be capable to lead projects to improve business performance and maintain sustainability.

  • Demonstrated proficiency in computer skills and network knowledge.

  • Strong skills in presentation, word processing, and spreadsheet applications.

  • Demonstrated success in analysis driven problem solving.

  • Excellent verbal, written and presentation skills.

  • Ability to work effectively in a high-pressure, time-sensitive environment.

  • Ability to effectively collaborate with cross functional teams and influence without authority or title.

  • Ability to maintain confidential and sensitive materials and information.

  • Ability to work in team environment, hand-in-hand with client, and deliver solid results in a demanding work environment.

  • Ability to establish effective working relationships with client personnel.

Subject Matter Expert Qualifications:


In addition to the general qualifications required for a Lean Manufacturing position, it is desirable, although not essential, that the Lean Manufacturing consultant have one or more of the following Subject Matter Expertise Qualifications:


  • Ten (10) years of related job experience preferred.

  • Bachelor’s degree in Engineering, Technical or Business is preferred. Equivalent is accepted.

  • Certification or certificate in one of the following preferred: Lean Manufacturing, Six Sigma and/or Project Management.

  • Knowledge of lean manufacturing methodology, quality issues, and problem solving.

  • Experience with most of the following tools:

    • Workplace Organization/Visual Management

    • Kaizen Planning and Execution

    • Bottleneck Analysis

    • Waste Identification

    • Continuous Flow and Line Layout

    • Quality Improvement and Error Proofing

    • Change Management

    • Material Flow and Kanban

    • Level Scheduling

    • Problem Solving and Root Cause Analysis

    • Project Management

    • Setup Reduction

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