Continuous Improvement Manager - Malibu Boats

Summary

The Continuous Improvement (CI) Site/Brand Lead is responsible for driving operational excellence across assigned MBI manufacturing operations, supporting the end-to-end operations, including production of premium boats and marine components. This role partners closely with plant and MBI leadership to enhance performance in hull fabrication, assembly, upholstery, rigging, and finishing-while preserving the craftsmanship and brand quality MBI is known for.

A core accountability of this role is the reduction of Cost of Poor Quality (COPQ) through disciplined problem-solving, defect elimination, and process control. The CI Lead acts as a hands-on change agent, deploying feasible methodologies (that include Lean principles) in a high-customization environment while strengthening a culture of accountability and continuous improvement.

Key Responsibilities

Cost of Poor Quality (COPQ) Reduction & Problem Solving (PRIMARY DELIVERABLE)

• Own plant-wide COPQ reduction strategy, including:

• Baseline accuracy

• Internal failures (scrap, rework, repair hours)

• External failures (warranty, dealer claims, field issues)

• Extended appraisal costs (inspection inefficiencies)

• Align with MBI Quality initiatives by co-establishing brand/site baseline COPQ metrics and drive year-over-year reduction targets.

• Lead structured problem-solving activities by using:

• A3 thinking

• Root Cause Analysis (RCA)

• 8D / DMAIC methodologies

• Facilitate cross-functional problem-solving activities (workshops, coaching, training, etc.) on top external (warranty) and internal (plant losses), including:

• Inspection

• Rework

• Gelcoat and cosmetic defects

• Upholstery rework

• Electrical and functional system failures

• Ensure permanent corrective actions with validation, standardization, and follow-up audits.

• Build capability across teams to solve problems at the root cause-not symptoms.

• Create transparency through COPQ dashboards and integrate into daily management.

Operational Excellence in Premium Boat Manufacturing

• Lead continuous improvement initiatives across key brand/site production processes:

• Parts and component assembly

• Fiberglass hull/deck layup

• Upholstery and interior finishing

• Rigging (electrical, ballast, surf systems)

• Final assembly, detailing, and water testing

• Improve flow and reduce bottlenecks in large-product, station-based assembly.

• Optimize takt alignment and line balancing in high-mix production.

Lean Deployment (Craftsmanship + Efficiency)

• Implement Lean tools while protecting Malibu's premium quality standards:

• Standard Work with built-in quality controls

• Visual Management for production and quality performance

• 5S in high-visibility, finish-critical areas

• Layered Process Audits (LPA)

• Optimal setup and controls leading to defect and COPQ reduction

• Target waste reduction in:

• Resin and composite material usage

• Rework loops and repair stations

• Labor inefficiencies driven by variation

Quality & Brand Protection

• Partner with MBI Quality to protect the premium brand reputation.

• Improve first-pass yield (FPY), reduce defects per unit (DPU), and reduce defect escape rates.

• Drive mistake-proofing (poka-yoke) in critical systems affecting:

• Safety

• Performance

• Customer-visible quality

• Connect plant metrics directly to dealer and customer satisfaction.

Customer & Dealer Experience Integration

• Translate dealer feedback and warranty trends into actionable improvement plans.
• Close the loop between field issues and plant corrective actions.
• Prioritize improvements that enhance the on-the-water customer experience.

Performance Management & Visual Systems

• Establish plant-wide SQDC and COPQ visual management systems.

• Track and drive key KPIs:

• COPQ as % of sales

• Rework hours per boat

• FPY and/or DPU

• Warranty cost per unit

• Throughput and on-time delivery

• Lead daily Gemba and tiered accountability meetings.

Production Scaling

• Support ramp-up/down aligned to demand cycles.
• Improve workforce flexibility via cross-training and standard work.
• Maintain quality discipline during high-volume peak periods.

Culture & Capability Building

• Support growth of problem-solving capability at all levels of the organization.
• Coach supervisors and team leaders on structured CI and defect elimination.
• Drive accountability for "build it right the first time" mindset.
• Increase employee engagement in kaizen and continuous improvement.

Project Leadership & Execution

• Lead a pipeline of CI projects with measurable impact on COPQ and operational performance.
• Partner with Engineering, Production, Quality, and Supply Chain.
• Ensure sustainability through standard work, audits, and leader standard work.

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