Continuous Improvement Manager
Company: Graham Packaging
Posted on: January 15, 2022
Graham Packaging is a leading manufacturer of sustainable
packaging. From the kitchen to the laundry room, Graham Packaging
is part of your everyday life. They're the kind of people you want
as your friends and neighbors as well as your partners and
suppliers. By building strong relationships and creating value for
our customers, our employees embody the innovative spirit that's
inherent to Graham. We truly are people building a better
Graham Packaging is seeking a dynamic and multidisciplinary
Continuous Improvement Manager to optimize plant systems,
production line and equipment performance, and product quality. The
Continuous Improvement Manager will be skilled in assessing and
diagnosing the root causes of problems that lead to defective
products, production yield loss and reduced productive uptime. The
Continuous Improvement Manager will work with plants to develop and
manage A3 projects to systematically address the Pareto of
improvement opportunities using Lean tools and the Graham
Operational Excellence (OPEX) continuous improvement process. The
Continuous Improvement Manager will be knowledgeable in the
fundamentals of lean manufacturing including reduction of
variability, waste elimination, and theory of constraints to drive
continuous improvement. The position, regionally based, has CI
responsibility for the Graham network of plants. - Each CI has a
focus area such as Rapid Change-Over, DOE / FMEA & 8D Complex
Problem Solving, Graham Operating System - CI Element, Yield &
Materials Kaizen, and Intelligent Factory.
Essential Duties and Responsibilities
The Continuous Improvement Manager's responsibilities are to:
Use observation, questioning and data measurement to fully
understand and categorize yield and uptime issues.
Identify and eliminate sources of variation that lead to changes to
the Standard Operating Condition (SOC).
Facilitate problem solving to root cause elimination and permanent
reduction of variance.
Analyze lines for constraints and bottlenecks to achieve continuous
Advocate for the Voice of the Customer (VOC) via process capability
and defect elimination.
Assess standard work artifacts and training to identify the origin
of production flow issues.
Contract or otherwise coordinate third parties to perform equipment
or system assessments.
Conduct timing and point of loss yield studies to identify the loss
Perform data analysis and prepare written reports in order make
visible the true nature of problems and opportunities.
Develop a detailed root cause analysis for each problem, where each
root cause is validated through testing, i.e. the condition or
defect can be turned on or off.
Develop countermeasures that could range from basic problem
containment to system repair to equipment replacement.
Generate and communicate implementation plans using Gantt charts
and work breakdown structures.
Coordinate central Operations & Engineering resources or third
parties to staff implementation plans as necessary.
Formulate strategic improvement hypotheses within the A3 Thinking
Facilitate Problem Solving by leveraging/modeling the DMAIC process
Lead Daily Management processes to validate that actions lead to
desired performance improvements.
Support deployment of Lean tools such as 5S, Visual Factory Aids,
SMED concepts, VSM, VOC and Poke Yoke to improve plant safety,
quality and throughput performance.
Proactively seek problems for resolution and quantify the
anticipated benefit of solving each particular problem.
Follow through to assess and report on achieving desired
Ensure appropriate standard work is developed and in place to
minimize problem reoccurrence.
Education and/or Work Experience Requirements:
BS degree in Operations, Engineering, Manufacturing related
Experience in an structured problem solving and continuous
improvement mindset workplace
At least 7 years of experience working in plant operations in
multi-line manufacturing plant
Experienced working in the plastics industry
Core Proficiencies and Skills
The following skills and proficiencies are essential requirements
of the position:
Strong understanding of Operational Excellence, Lean principals,
statistics and data analysis.
Rapid Changeover implementation experience using Lean tools,
Standard Work, and Project Management tools
Proficient applying DMAIC or PDCA continuous improvement
Deep knowledge in production line flow, yield and uptime analysis
Knowledge of line design that optimizes line uptime i.e.
throughput, queueing, accumulation and bottleneck analysis.
Skilled applying manual line measurements (e.g. Tic Charts) and
other data collection methods and measurement methods to understand
unit flow and loss characteristics
Experienced in optimizing the performance of:
o - - Factory systems and line process inputs
o - - Information flow
o - - Raw materials flow, conveyance, blending, and drying
o - - Blow Molder lines for throughput
o - - Injection Molding lines for capability
o - - Quality systems for defect elimination
o - - EHS systems for a safe working environment
o - - Operational systems for waste elimination
o - - People development for engagement and ownership
Skilled in facilitation of Problem solving including 8D, FMEA,
Kaizen, Lean tools
Strong written and verbal communication skills
Strong coaching, mentoring skills
Graham Packaging is an Equal Opportunity Employer. All qualified
applicants will receive consideration for employment without regard
to race, color, sex (including pregnancy), sexual orientation,
religion, creed, age, national origin, physical or mental
disability, gender identity and/or expression, marital status,
veteran status or other characteristics protected by law.
Keywords: Graham Packaging, Modesto , Continuous Improvement Manager, Executive , Modesto, California
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