Director of Thrive providing leadership and direction for the Thrive initiative supporting churches in Canada and the US. Ensuring strategic planning, resource development, and staffing are effectively managed.
About the role
- Director of Process Excellence at Northrop Grumman responsible for engineering and lean manufacturing. Leading initiatives to improve productivity and quality across manufacturing processes.
Responsibilities
- Develop and execute the engineering driven, lean focused roadmap that delivers higher quality, higher productivity, lower cost, and safer workplaces
- Lead the design, qualification (IQ/OQ/PQ) and scale‑up of manufacturing processes, equipment, fixtures, and tooling for new products and product revisions
- Own the NPI hand‑over from R&D to the shop floor, ensuring cost, cycle‑time, and yield targets are met
- Drive retrofits, automation upgrades, and line redesigns that improve OEE and reduce change‑over time (SMED)
- Create and maintain robust work instructions, SOPs, and process specifications that are the “single source of truth” for production
- Perform takt‑time analysis, line balancing, and capacity modeling to meet forecast demand while minimizing labor and equipment bottlenecks
- Design/optimize plant layouts, cellular manufacturing cells, and material flow (value‑stream mapping) for maximum efficiency and minimal handling
- Use discrete‑event simulation, digital twin tools, and data analytics to evaluate “what‑if” scenarios before physical changes are made
- Conduct time‑studies, method‑studies, and ergonomic assessments to set standard labor times and reduce fatigue
- Build and sustain a plant‑wide lean system (5S, visual management, pull systems, Kanban, JIT) tailored to each operation
- Lead a certified Black‑Belt/Green‑Belt program, prioritize high‑impact projects, and ensure statistically‑validated results (DEFECT‑Reduction, Cycle‑Time, Cost)
- Translate corporate strategic goals into annual/quarterly lean objectives; cascade metrics down to the shop floor
- Conduct daily Gemba walks, coaching frontline supervisors on problem‑solving (A3, 5‑Why) and rapid improvement cycles
- Recruit, develop, and retain a high‑performing ME/IE/Lean team (engineers, analysts, facilitators)
- Mentor plant leaders and front‑line teams in lean thinking, data‑driven decision making, and change management
- Create a “continuous‑improvement as a habit” culture measured by participation rates and sustained gains
- Define the KPI set for ME, IE, and Lean (OEE, SCRAP, First‑Pass Yield, Labor Hours per Unit, Change‑over Time)
- Integrate MES/ERP data streams into real‑time dashboards; ensure data integrity for decision making
- Champion the use of advanced analytics (statistical process control, predictive maintenance, AI) to pre‑empt losses
- Build business cases (ROI, payback) for all engineering and lean projects; track actual savings vs. target
- Partner with Finance to embed process costs into product costing and margin analysis
- Embed EHS and Quality requirements (ISO/TS, GMP, IATF) into every process design and lean activity
- Conduct risk assessments (PFMEA, Process Hazard Analysis) and drive corrective actions promptly
Requirements
- Bachelor's degree with 10 plus years of relevant experience OR Master's degree with 8 plus years of relevant experience
- 10 plus years progressive experience in manufacturing/industrial engineering
- At least 5 years in a leadership role focused on lean/continuous improvement
- Certified Lean Practitioner
- Proven ability to lead cross‑functional, matrixed teams and to influence senior leadership without direct authority
- Proven ability to build and maintain high performing teams
- Proven ability to take ownership and be accountable with an “owners” mindset
- Strong business/financial acumen, keen organizational skills, and excellent problem-solving ability
- Ability to obtain and maintain a security clearance up to Top Secret
Benefits
- Health insurance coverage
- Life and disability insurance
- Savings plan
- Company paid holidays
- Paid time off (PTO) for vacation and/or personal business
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