Lean Manufacturing Process Specialist
North East Group is seeking a hands-on Manufacturing Process & Fixture Specialist to contribute to continuous improvement within our truck body manufacturing operations. This role involves identifying and implementing process enhancements, alongside designing and developing jigs and fixtures to elevate efficiency, consistency, and production output. This is a full-time, onsite position, based at our Northeast Engineering facility, with occasional travel to suppliers and partner workshops. The role reports to the Head of Manufacturing.
Key Responsibilities
- Process Analysis and Improvement
- Lead comprehensive process mapping and value stream analysis for truck body fabrication and assembly.
- Utilise Six Sigma tools and statistical methods to pinpoint root causes of variation and defects.
- Design and implement Kanban systems for material flow, work-in-progress control, and replenishment.
- Jig and Fixture Design and Implementation
- Produce design briefs, CAD concepts, and engineering change requests for jigs, fixtures, and workholding.
- Prototype, test, and iterate fixtures in collaboration with workshop and production teams.
- Ensure fixtures provide repeatability, ergonomic safety, quick changeover, and maintainability.
- Standardisation and Control
- Develop and maintain Standard Operating Procedures (SOPs), work instructions, visual controls, and inspection jigs.
- Implement poka-yoke and other mistake-proofing measures where appropriate.
- Validate process changes through pilot runs and formal capability studies.
- Data, Reporting and Continuous Improvement
- Define and track key process metrics; present data-driven business cases and cost–benefit analyses.
- Maintain improvement logs, change records, and validation documentation.
- Coach and train production staff in lean methods, Kanban, and new fixtures/processes.
- Research and Benchmarking
- Research best practices in truck body manufacturing, modular assembly, automated welding, and material handling.
- Translate external best practices into practical, shop-floor-ready recommendations.
Objectives and Key Performance Indicators
- Primary Objectives
- Increase repeatable quality and reduce variation across truck body production.
- Raise production throughput while reducing rework and scrap.
- Deliver robust, maintainable jigs and fixtures that reduce cycle time and operator dependency.
- Key Performance Indicators
- Quality: Reduction in defect rate and rework percentage.
- Throughput: Increase in units produced per shift/week.
- Cycle Time: Reduction in cycle time for targeted operations.
- Process Capability: Improvement in Cp/Cpk for critical dimensions.
- Inventory: Reduction in WIP and lead time via Kanban implementation.
- Return on Investment: Measured payback period for fixture and process investments.
Required Skills and Qualifications
- Technical Qualifications
- Tertiary qualification in Mechanical Engineering, Manufacturing Engineering, or equivalent.
- Six Sigma Green Belt minimum; Black Belt preferred.
- Demonstrated experience implementing Kanban and lean manufacturing systems.
- Proficiency with CAD tools and ability to produce fixture concepts and engineering documentation.
- Experience
- Proven track record in jig/fixture design, prototyping, and shop-floor implementation.
- Experience in truck body, commercial vehicle, or heavy fabrication manufacturing preferred.
- Strong background in welding processes, assembly fixturing, and dimensional control.
- Behavioural Competencies
- Data-driven problem solver with strong statistical thinking.
- Effective communicator able to bridge engineering and production teams.
- Practical, hands-on approach with respect for shop-floor expertise.
- Project management skills and ability to deliver to timelines and budgets.
Deliverables Authority and Working Relationships
- Deliverables
- Process maps, capability studies, and improvement proposals with cost–benefit analysis.
- CAD concepts, prototype fixtures, validation reports, and updated SOPs.
- Training materials and roll-out plans for implemented changes.
- Authority
- Authority to initiate pilot trials and minor engineering changes within agreed budgets.
- Authority to recommend capital expenditure for fixtures and tooling subject to management approval.
- Key Interfaces
- Production Supervisors and Operators
- Quality Assurance and Inspection Teams
- Workshop Fabrication and Maintenance Teams
- Design Engineering and Procurement
Application Process and Selection Criteria
- Application Requirements
- CV with relevant project examples of jig/fixture development and process improvements.
- Brief cover letter outlining Six Sigma experience and a summary of a measurable improvement you led.
- Portfolio or examples of CAD concepts, validation reports, or before/after metrics where available.
- Selection Stages
- CV and portfolio shortlisting.
- Technical interview including case study on process improvement and fixture design.
- Practical assessment or site visit to review candidate approach to a real shop-floor problem.
- Final interview with senior management.
Location: Burton Work Type: Full-time Work Arrangement: Onsite