Manufacturing & Ops Consultant - IX

We are seeking a Manufacturing & Operations Consultant with deep Lean and Six Sigma expertise to lead high-impact operational improvement initiatives across client environments. Our work is rooted in manufacturing and extends across the broader operation, including supply chain, distribution, maintenance, and supporting business processes.

This is a hands-on role focused on execution. You will work directly in plants, warehouses, and operational settings to diagnose issues, design practical solutions, and implement change that delivers measurable results. You will also coach client teams, mentor Green and Yellow Belts, and help clients build continuous improvement capability that lasts.

What Good Looks Like

You'll thrive in this role if you:

• Are equally comfortable on the shop floor, in the warehouse, and in the boardroom
• Can quickly identify waste, flow issues, variation, and root causes
• Balance statistical rigor with practical judgment and speed
• Bring structure and direction to ambiguous situations, defining the work and driving execution
• Proactively identify risks, remove roadblocks, and keep work moving forward
• Work as part of a high-performance team, sharing information openly and stepping in where needed to ensure team success
• Communicate clearly and confidently at every level, from IE teammates and frontline teams to senior leaders
• Naturally coach, teach, and elevate others
• Build trust quickly across all levels of an organization
• Adapt quickly to new industries and operating environments, applying core operational principles regardless of context

What You'll Do

Diagnose & Analyze. Assess current-state operations end to end, including production, material flow, supply chain, and support processes, to identify waste, bottlenecks, variation, and flow constraints. Lead value stream mapping and process walks. Use statistical analysis (hypothesis testing, regression, capability analysis, MSA) and data tools (Minitab or JMP, Excel, Power BI) to validate root causes and quantify opportunity.

Design & Plan. Develop future-state solutions including flow, layout, labor models, capacity, inventory and pull systems, and process improvements. Support 3P, facility design, and Design for Manufacturing (DFM) initiatives where applicable. Build practical, executable implementation plans tied to measurable outcomes.

Implement & Execute. Own and drive execution of defined workstreams, ensuring progress against plan, timelines, and deliverables. Plan and facilitate kaizen events and rapid improvement activities. Implement Lean tools including standard work, visual management, 5S, SMED, kanban/pull, and TPM. Lead DMAIC projects from charter through control, applying DOE and SPC where appropriate. Coordinate across client stakeholders and IE team members to ensure alignment and execution. Integrate digital, data, and AI-enabled insights where applicable.

Sustain & Coach. Implement management systems such as tiered meetings, KPIs, leader standard work, control plans, and accountability structures. Coach frontline leaders and teams to sustain improvements. Mentor and deliver Lean Six Sigma training as needed.

Build CI Capability. Help clients stand up or strengthen continuous improvement programs, including deployment strategy, project selection and chartering, pipeline management, governance, and strategy deployment (hoshin kanri). Partner with client finance to validate project savings.

Communicate & Influence. Present insights, plans, and results to client leadership. Facilitate alignment across cross-functional teams. Support decision-making with clear, data-backed recommendations. Contribute to consistent, high-quality delivery across IE engagements.

How We Deliver at Implementation Engineers

At Implementation Engineers, how we deliver is just as important as what we deliver. We operate with a structured, disciplined approach that ensures our work is clear, aligned, and drives measurable results.

Act as a Change Agent. Support clients in adopting and sustaining improvements through clear communication, coaching, and engagement.

Apply Project Management Discipline. Plan, execute, and monitor work using IE's standard delivery processes and tools.

Operate Within IE Governance & Standards. Maintain an actively managed project plan, follow established change management processes, and ensure consistent, proactive communication with stakeholders.

Maintain Program Transparency. Keep project documentation current, organized, and accessible, ensuring clear visibility into progress and outcomes.

Leverage IE Tools & Systems. Use tools such as Smartsheet and Microsoft Teams to support planning, tracking, collaboration, and reporting.

Success in This Role Looks Like

• Delivery against client-defined objectives and committed outcomes
• Measurable impact aligned to the engagement scope, such as hard and soft savings validated by client finance and gains in safety, quality, delivery, and cost (e.g., OEE, first-pass yield, DPMO, lead time, inventory turns)
• Workstreams that are clearly structured, actively managed, and delivered on plan, with clear visibility and accountability
• Strong adoption of new processes, systems, and behaviors within the client organization
• Client CI capability that outlasts the engagement, including trained and certified belts and an active project pipeline
• Sustainable results that continue beyond the engagement
• Strong collaboration within IE teams, contributing to consistent, high-quality delivery across engagements
• High trust and credibility with client stakeholders, leading to follow-on work

Required Experience & Capabilities

Must Have

• Bachelor's degree in Engineering (Industrial, Manufacturing, Mechanical, Process, or similar) preferred; degrees in Operations Management, Supply Chain, or related fields with strong technical depth will be considered
• 7-10+ years in manufacturing, operations, or operations consulting environments
• Lean Six Sigma certification (ASQ, IASSC, or a recognized corporate program) with a track record of completed DMAIC projects and validated results.
• Deep Lean expertise, including value stream mapping, kaizen facilitation, standard work, pull systems, and management systems
• Proficiency in statistical analysis (hypothesis testing, regression, DOE, SPC, MSA, process capability)
• Proven experience leading operational improvement initiatives and workstreams, with the ability to plan, execute, and deliver against defined objectives
• Strong project management discipline, including planning, tracking, and risk management
• Advanced Excel skills; Power BI strongly preferred
• Experience working in plant / shop-floor environments
• Strong communication skills with executive presence
• Willingness to travel to client sites

Nice to Have

• Master Black Belt certification; MBA or advanced degree
• Experience across multiple manufacturing industries (e.g., automotive, aerospace, food & beverage, chemical, industrial)
• Exposure to both discrete and process manufacturing environments
• Experience in supply chain, distribution / warehouse, or maintenance and reliability operations
• Experience with 3P, facility design, or layout optimization
• Design for Manufacturing (DFM) experience
• Experience training and certifying belts or building a CI program
• Exposure to digital manufacturing, automation, or AI-enabled operations