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 good.
We are seeking to add a talented AOS Manager to our Aleris Operating System (AOS) team at the Clayton, NJ plant. The purpose of this role is to lead the implementation, training, teaching, coaching, support, and management of the implementation of a world class continuous improvement system using lean and six sigma techniques in our Clayton, NJ facility. The role will require approx. 10% travel to the various sites within North America. This position is a key support and tactical execution role of the cornerstones of the Aleris Operating System – Reliable People(Operations), Reliable Process, Reliable Assets.
Lead and support implementation, building and development of a world class AOS system at the Clayton facility with support from the Global and Regional AOS team: Reliable People (Lean Operations), Reliable Process (Aleris Process Control), Reliable Assets (Equipment Reliability). Plant champion of the AOS Roadmap and strategic A3. Assist with the Regional and Global teams on program development as necessary.
Train and develop leaders on lean principles, cultural transformation, A3 development, and the lean leader mindset. Engage with all levels of the organization to drive a lean mindset.
Openly and effectively communicate about continuous improvement, build credibility through relationships, and provide leadership to the program.
Spend 25% of working time at Gemba (on the plant floor) focusing on employee engagements and teaching the lean concepts.
Apply the Aleris Lean activities and tools (6s, A3 Thinking, SMED, RCFA, TWI, Standardized Work, VSM, TPM, APC, Equipment Reliability and Problem Solving) to the day to day business. Use appropriate measurement, analysis, and evaluation methods to accurately identify and document improvements.
Focus the plant organization towards improvements on safety and reliability (people, process, equipment) through lean techniques and employee engagement.
Drive change within the plant teams to enable Aleris to continuously improve performance, which includes managing the transformation roadmap, and leveraging Information Centers for continuous improvement, and creating a visual workplace. Identify short-, mid-, and long-term wins that will transform the culture and produce results.
Provide event follow-up to monitor the progress of planned improvement implementation to assure timely action, appropriate support, and achievement of expected tangible benefits.
Lead/facilitate projects and/or events which address plant and region value-at-stake opportunities, helping to drive improvements in all facets of the operations.
Facilitate, lead and direct Root Cause Failure Analysis of significant People, Process, Equipment related downtime events; implement permanent corrective actions to mitigate probability of reoccurrence.
Lead/facilitate FMEA(Failure Mode Effects Analysis) on all equipment/processes in the plant.
Be a resource for operations, maintenance, HSE and supply chain in support of delivering the plant business objectives.
Bachelor’s degree preferably in engineering, manufacturing/operations; or an equivalent level of degree with related experience.
3+ years of experience with TPM, Lean, kaizen/six sigma events and supporting lean transformation with proven results and implementations in a manufacturing environment.
Lean certification strongly desired, including both education and the hands on ability to participate in teams and implement improvements.
Excellent interpersonal, written, verbal communication skills and organization skills, must be comfortable teaching and facilitating at all levels of the organization.
Proven ability to successfully participate in cross functional teams, and implement improvement within an established time frame, then sustain improvements.
High energy, data driven, and results oriented.
Must be proficient in MS Word, MS Excel, MS PowerPoint, MS Project, Oracle, and various analysis tools (minitab, etc).
Willingness to travel approximately 10% of the time.
Aluminum Casting or Rolling Experience.
Process/Technical or Operations experience with a proven track record of lean concepts.
CMRP or SMRP certification.
Lean Six Sigma Black Belt/Master Black Belt.
Experience in a leadership role.
Majority of the work requires working in an industrial environment where employee may be exposed to fumes, airborne particles, overhead and other mobile equipment. Noise level in the environment is loud. Parts of tasks are accomplished in an air-conditioned plant environment.
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.