Continuous Improvement Specialist

Aleris International, Inc Uhrichsville , OH 44683

Posted 3 months ago

Overview / Job Summary

Aleris is a global leader in the manufacture and sale of aluminum rolled products, with approximately 14 facilities in three geographically aligned business units in North America, Europe and China. We serve a variety of end-use industries, including aerospace, automotive, defense, building and construction, transportation, packaging, and consumer goods. We are currently seeking to add a talented AOS Specialist

  • Reliable Operations/Process to our Aleris Operating System (AOS) team.

Purpose of this role is to be a lead AOS team member on the implementation, training, teaching, coaching, and management of a world class continuous improvement system utilizing lean and six sigma techniques in our Uhrichsville Ohio facility. The role will require approximately 10% travel to various sites in North America. This position is a key support and tactical execution role of one of the cornerstones of our Aleris Operating System Reliable Process.

Responsibilities Include

Support the implementation of a world class AOS System: Reliable People (Lean Operations) Reliable Process (APC) and Reliable Assets (Equipment).

  • Teach and train the AOS curriculum for engineers, technical support, operations, maintenance and staff throughout the facility.

  • Provide coaching and mentorship of plant teams in the impact they have on process and operations reliability.

  • Support cultural transformation within the roll out of lean transformation.

  • Lead the identification of Key Process Parameters (KPPs) through problem solving, analysis of best practices and/or lessons learned.

  • Support the business by defining standards on processing windows, owners, work instructions, KPPs follow-up, APC indicators, communication on APC indicators, APC audits.

  • Identify and implement the right methodologies for analysis of process stability.

  • Support the Plant and Regional Managers of Reliable Operations, Reliable Process and Reliable Assets through project work and data analysis.

  • Support the plant teams through facilitation and participation of advanced problem solving techniques.

  • Demonstrate effective team facilitation skills to engage the various teams to deliver improvement results on time.

  • Implement the standardized AOS toolbox, including core tools: 5s, A3 Thinking, SMED, RCFA, TWI, Standardized Work, VSM, TPM, APC, Equipment Reliability and Problem Solving.

  • Coach/facilitate/participate in plant shop floor teams to enable Aleris to continuously improve performance, leverage Information Centers for continuous improvement, and create a visual workplace, solve complex problems.

  • Interface with plant, regional and global reliability resources and external consultants to benchmark and develop and closes gaps in the area of process reliability.

  • Develop and participate in process and operations auditing at all levels of the organization. Make recommendations and drive to implementing sustainable solutions.

  • Assist leadership in the development of strategic A3s for the business and plants.

  • Coordinate event follow-up (30/60/90 day reviews) to monitor the progress of planned improvement implementation to assure timely action, appropriate management support, and achievement of expected tangible benefits.

  • Lead/facilitate projects and/or events which address value-at-stake opportunities, helping to drive improvements in all facets of operations.

  • Participate in AOS and HSE audits. Drive solution implementation.

  • Identify and focus on short and long-term wins that will transform the culture and produce results.

  • Lead Root Cause Failure Analysis of significant People, Process, Equipment related downtime events at Plant locations; implementing permanent corrective actions to mitigate probability of reoccurrence.

  • Facilitate FMEA(Failure Mode Effect Analysis) on equipment and processes within the facility.

  • Be a leader within the AOS organization engage the workforce.

  • Openly and effectively communicate about continuous improvement, build credibility through relationships, and provide leadership to the program.

  • Be a resource for operations, maintenance, HSE and supply chain in support of delivering the business objectives.

  • Use, teach and coach lean and six sigma methodology and proactive problem solving.

  • Spend 75% of working time at Gemba (on the plant floor) focusing on employee engagements.

Required Qualifications

Required Qualifications:

  • Lean/Six Sigma Certification
  • Both course work and hands on.
  • Proven ability to work independently and successfully facilitate cross functional teams, while implementing improvement within an established time frame.

  • Well Organized, High energy, data driven, and results oriented.

  • Excellent interpersonal, written, verbal communication skills and organization skills, must be comfortable teaching and presenting to large groups at all levels of the organization from shop floor to CEO.

  • Must be proficient in MS Word, MS Outlook, MS Excel, MS PowerPoint, Oracle, and various analysis tools (minitab, etc).

  • Willingness to travel approximately 10% of the time.

Preferred Qualifications:

  • Bachelor's degree strongly desired, preferably in engineering, manufacturing/operations; or an equivalent level of degree/experience.

  • Aluminum Casting or Rolling Experience

  • 2+ years of experience facilitating, coaching and implementing TPM, Lean, kaizen/six sigma events and driving lean transformation with proven results and implementations in a manufacturing environment.

  • SPC training/certification

  • Process/Technical/Operations/Maintenance experience

  • Lean Six Sigma Green Belt/Black Belt Certification

  • SPC training/certification

  • CMRP Certification

  • Process/Technical/Operations/Maintenance experience

Aleris is an equal opportunity employer and supports diversity in the workplace. Qualified applications will receive consideration for employment without regard to their race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran. Our HR teams will reach out to the applicants who met the qualifications and most closely aligned with requirements of the positions.

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Continuous Improvement Specialist

Aleris International, Inc