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Continuous Improvement Manager

San Luis Obispo, California, United States

Join us at Zone 5 Technologies where innovation and cutting-edge technology drive pioneering advancements in unmanned aircraft systems (UAS). Based in the vibrant city of San Luis Obispo CA, we're seeking talented individuals to join and contribute to our growing team.

We thrive on pushing boundaries and inventing solutions to real-world challenges. Join a community of forward-thinkers who collaborate to create impactful products with a global reach. Our team, consisting of engineers and professionals, is prepared to overcome new frontiers and deliver innovative solutions in the field of unmanned aircraft systems.

We are seeking a results-driven Production Continuous Improvement Manager to coach teams in scientific problem-solving while delivering measurable operational improvements through Toyota Kata methodology. This hands-on role requires an individual who can develop improvement capabilities across production teams while executing targeted improvement projects that drive quantifiable results in our high-growth manufacturing environment. 

Key Responsibilities 

Toyota Kata Implementation & Coaching:

  • Coach production teams through the Improvement cycle: understand current condition, establish target condition, conduct PDCA experiments, and reflect on learning 
  • Guide teams in setting appropriate challenge directions and target conditions aligned with production goals 
  • Facilitate daily coaching cycles with team leaders and supervisors to develop scientific thinking patterns 
  • Support teams in conducting rapid PDCA experiments on production processes, equipment performance, and workflow optimization 
  • Work hands-on with teams to identify obstacles preventing achievement of target conditions 

Process Improvement & Results Delivery: 

  • Lead by example in applying Toyota Kata methodology to tackle complex production challenges while managing multiple concurrent improvement projects 
  • Guide teams through systematic problem-solving using Plan-Do-Check-Act cycles for cycle time reduction, yield improvement, and defect elimination 
  • Conduct detailed analysis of production lines, manufacturing processes, and workflow bottlenecks using Lean tools (5S, value stream mapping, standardized work) 
  • Execute targeted Six Sigma DMAIC projects when appropriate, integrated with Toyota Kata experimentation approach 
  • Perform hands-on root cause analysis using statistical tools and data analysis to solve production problems 

Performance Measurement & Learning Documentation:

  • Establish and track production KPIs including OEE (Overall Equipment Effectiveness), cycle time, defect rates, and throughput 
  • Monitor progress toward target conditions and coach teams through obstacle identification and countermeasure development 
  • Generate monthly reports showing both cost savings/productivity improvements and team learning progression 
  • Maintain coaching records and experiment logs to track learning and capability development 
  • Validate improvement results through statistical analysis and control charts 

Capability Development & Culture Building:

  • Develop improvement kata and coaching kata capabilities in leadership 
  • Train production teams on scientific thinking, experimentation mindset, and learning from failure 
  • Create and maintain coaching cycles with team leaders across production areas 
  • Establish improvement kata practice routines while ensuring sustainability of implemented improvements 
  • Coach front-line supervisors on both Toyota Kata methodology and traditional Lean problem-solving tools 

Required Qualifications:

  • Bachelor's degree in industrial engineering, Manufacturing Engineering, Business Administration, or related field 
  • 7+ years hands-on experience in production environments implementing continuous improvement methodologies 
  • Toyota Kata certification or demonstrated experience with Improvement Kata and Coaching Kata methodologies 
  • Lean Six Sigma Black Belt certification preferred, or equivalent demonstrated proficiency with Lean tools and statistical analysis 
  • Strong coaching and mentoring skills with ability to develop scientific thinking in others 
  • Experience with PDCA experimentation, hypothesis testing, and systematic problem-solving approaches 
  • Proficiency with statistical analysis software and data visualization tools 
  • Demonstrated track record of delivering measurable results in manufacturing operations 
  • Strong project management skills with ability to manage multiple concurrent initiatives 

Preferred Qualifications:

  • Experience in aerospace, defense, automotive, or high-precision manufacturing 
  • Knowledge of advanced manufacturing concepts 
  • Familiarity with ERP systems and manufacturing execution systems 
  • Certification in project management (PMP) or change management 

Working Environment:

  • This role requires 80% time on the production floor working directly with manufacturing teams.
  •  Hands-on problem solving, data collection, and implementation activities in an active manufacturing environment. 

Pay range for this role

$125,000 - $175,000 USD

What's in it for you:

Benefits: 

  • Competitive total compensation package 
  • Comprehensive benefit package options include medical, dental, vision, life, and more.
  • 401k with company-match 
  • 4 weeks of paid time off each year
  • 12 annual company holidays

Why Join Zone 5 Technologies?

  • Innovative Environment: Work on cutting-edge technology that is shaping the future of defense and aerospace.
  • Collaborative Culture: Join a team of passionate professionals dedicated to pushing the boundaries of what’s possible.
  • Career Growth: Opportunities for professional development and career advancement.

If you are passionate about unmanned aircraft technology and want to be a part of a dynamic and growing company, we would love to hear from you. Apply today and join the Zone 5 Technologies team! 

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.

Zone 5 Technologies is a federal contractor and participates in E-Verify to confirm employment eligibility. As required by law, we will verify the identity and employment authorization of all new employees using the E-Verify system. Learn more about your rights and responsibilities under E-Verify: https://www.e-verify.gov.

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