Senior Operational Excellence Manager in Tracy, California at Vaughan Buckley Construction

Job Title

Manufacturing Engineering & Continuous Improvement Manager

Department

Manufacturing Engineering & Quality

Reports To

Manufacturing Engineering & Quality Director

Role Summary

The Manufacturing Engineering & Continuous Improvement Manager is responsible for designing, optimizing, and continuously improving manufacturing processes in a modular construction environment. This role leads the deployment of Lean / TPS-based manufacturing systems, drives productivity, quality, safety, and cost improvements, and ensures scalable, repeatable processes across production lines.

The position requires a strong balance of technical manufacturing engineering, hands-on continuous improvement leadership, and cross-functional collaboration with Production, Quality, Maintenance, Programming, and Supply Chain.

Key Responsibilities

Manufacturing Process Engineering

• Design and optimize process flow, layouts, capacity models, takt time, and standard work for modular construction lines (wood and/or steel).
• Support new and existing production lines by improving throughput, labor efficiency, and equipment utilization.
• Lead manufacturing engineering support for new product introductions and line expansions.
• Ensure manufacturing processes are robust, repeatable, and capable of meeting quality and delivery targets.

Continuous Improvement & Lean Deployment

• Lead the site Continuous Improvement (CI) roadmap, aligning initiatives with business priorities.
• Implement Lean Manufacturing and TPS principles, including:
  • Value Stream Mapping
  • Kaizen events
  • Waste elimination (Scrap, Motion, Waiting, Overprocessing, etc.)
• Manage a structured Kaizen pipeline and track financial and operational benefits.
• Drive cost reduction initiatives with measurable ROI.

Visual Management & Tier System

• Deploy and sustain visual management systems, including Tier boards and KPI dashboards.
• Support daily management routines such as Tier meetings and Gemba walks.
• Ensure key metrics (Safety, Quality, Delivery, Cost, Productivity) are visible, accurate, and actionable.

Productivity, Quality & Process Capability

• Improve process capability through:
  • Cycle time reduction
  • Standardization
  • Error-proofing (Poka-Yoke)
  • Workstation and material flow optimization
• Partner with Quality and Engineering to implement quality checkpoints, control plans, and problem-solving practices.
• Support root cause analysis and corrective actions for quality, safety, and productivity issues.

Standardization & Documentation

• Lead the creation and deployment of:
  • Standard Work
  • Operator Work Instructions (OWIs)
  • Setup standards
  • Preventive maintenance standards
• Support and audit 5S implementation across manufacturing areas.
• Ensure standards are embedded, trained, and audited routinely.

People & Cross-Functional Leadership

• Act as a technical and CI mentor to engineers, analysts, and production leaders.
• Collaborate closely with Production, Maintenance, Quality, Programming, and Supply Chain.
• Influence change on the shop floor through data-driven decisions and strong communication.

Qualifications

Required

• Bachelor’s degree in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or related field.
• 7+ years of experience in manufacturing engineering and/or continuous improvement roles.
• Proven experience implementing Lean Manufacturing / TPS in a production environment.
• Strong understanding of process flow, capacity planning, standard work, and CI tools.
• Hands-on experience in a factory setting; comfortable working on the shop floor.

Preferred

• Experience in modular construction, building products, or assembly processes in continuous lines.
• Experience with automated equipment, CNC/nailing systems, or high-mix production.
• Strong financial acumen with demonstrated ROI from CI projects.

Key Competencies

• Results-driven and execution-focused
• Strong problem-solving and analytical skills
• Ability to lead change and influence without authority
• Excellent communication across all organizational levels
• Structured, data-driven, and detail-oriented while maintaining a big-picture view

Performance Expectations

• Measurable improvements in productivity, cost, quality, and delivery
• Sustained Lean systems, not one-time events
• High engagement and participation in CI activities
• Clear financial ROI on engineering and CI initiatives

Salary Range: $140,000 to $165,000