Continuous Improvement Manager - Malibu Boats
On-siteLoudon, Tennessee, United States or Malibu, California, United States
Job Summary
Drive plant-wide Cost of Poor Quality (COPQ) reduction through A3 thinking, 8D, and DMAIC methodologies to eliminate internal and external failures. Lead continuous improvement initiatives across hull fabrication, upholstery, rigging, and final assembly while optimizing takt alignment and reducing resin waste. Implement Lean tools, visual management, and Layered Process Audits to protect premium brand quality and standardize work. Partner with engineering and quality teams to translate dealer feedback into actionable plans, close the loop on warranty trends, and coach supervisors on root cause resolution. Establish SQDC dashboards to track KPIs including first-pass yield, rework hours, and throughput during high-volume ramp-ups.
Required Qualifications
- Bachelor's degree in engineering, Manufacturing, Operations, or related field
- 8–10+ years of experience in manufacturing, continuous improvement, and/or operational excellence activities
- Strong experience driving quality improvement and cost of poor-quality reduction required
Desired Qualifications
- Demonstrated performance and experience in marine, automotive, RV, or other high-mix assembly environments preferred
- Strong project management, organizational, and analytical skills
- Excellent communication, training, and facilitation abilities
- Experience with data analysis, modern QMS tools, and advanced manufacturing concepts
- Deep expertise in Root cause problem solving (A3, 8D, DMAIC)
- COPQ analysis and budgetary impact modeling
- Lean manufacturing principles
- Experience with industry materials and finishing processes strongly preferred
- Lean Six Sigma certification (Green/Black Belt) preferred
- Strong leadership, team building, group facilitation, and change management skills
- Accountability, dependability, adaptability, and flexibility
- Coaching, mentoring
- Creative, innovative thinker
- Good decision making and judgment
- Ethics, integrity, honesty
- Willingness to learn
- Relentless focus on defect elimination and root cause resolution
- Passion for craftsmanship and premium product quality
- Data-driven decision-making with strong shop-floor instincts
- Ability to lead in high-variation, custom manufacturing
- Strong cross-functional leadership and influence
- Systems thinking and standardization
- Project management and execution
- Training and capability development
- Attention to detail and documentation rigor
- Change management
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