Director of Continuous Improvement

This newly created role in Gibson’s Operations Leadership Team aims to formalize and mature capabilities that are critical to the ongoing evolution of Gibson’s US-based manufacturing operations.  The Gibson name has the distinction of being the only major stringed instrument brand to be exclusively US-manufactured.  The successful candidate will be integral to furthering Gibson’s 131-year legacy of ‘made in America’ operational innovation by helping to develop and implement our new Lean focused strategy for safe and productive manufacturing.  This new strategy has the full engagement of our leadership team, providing a high impact opportunity for an experienced and energetic Lean leader to support a step-change in how we work.  

The ideal candidate draws from extensive Industrial Engineering, Lean Manufacturing, Shop Floor, and Six Sigma experience that will lead and support Gibson in substantially increasing efficiency, reducing waste, improving quality, expanding capabilities, and engaging all levels of the organization in daily improvement in service to our customers.   Additionally, candidates must have proven Change Management capabilities in similar environments to enable them to effectively engage our craft-based Team Members to contribute to, and adopt, efficient and effective ways of working.

The Director of Continuous Improvement will be adept at working cross-functionally in a matrix structure with high-caliber teammates in Quality Assurance, Procurement, Warehousing, Operations, Factory Leadership and Executive Leadership.  Critical to the success of this role is the collaboration on strategic CI initiatives and the development of Lean competencies across our manufacturing function and locations.  The Director of Continuous Improvement will be supported by a small number of direct reports who will provide leverage for managing key elements of our Lean program structure.

Extensive, direct knowledge of strategic, multi-site Continuous Improvement roadmap development and implementation is critical. We foster a high-performing and respectful work culture that revolves around a commitment to producing the iconic musical instruments that make Gibson legendary, and champion the craftspeople who make them. We value respect for people, product, and our customers.

The successful candidate must be motivated by the opportunity to start with a broad mandate and shape their role and team over time in partnership with Gibson’s senior operations leaders.

Essential Functions    

Continuous Improvement Strategy and Facility Support

-    Works with Operational Leadership to create an over-arching Gibson CI roadmap that focuses on the manufacturing facilities initially but highlights the opportunities across the organization.

-    Works closely with multiple facility leadership groups to tailor fit the Gibson CI roadmap to their specific facility by developing current -condition VSMs and gauging cultural readiness via multi-level interviews within the facility. 

-    Mentors project leaders in the execution of projects using Lean and Six Sigma tools and techniques.

-    Develops dashboards and operating rhythms that communicate progress and impact of projects to stakeholders and senior leadership.

-    Leads, coaches, and develops a team of continuous improvement professionals through a hands-on, shop-floor approach while fostering a high-performance culture focused on operational excellence.

-    Serves as a change agent, promoting a mindset of continuous improvement and operational efficiency throughout the organization.  Leads structured management activities, promoting the benefits of Lean practices in a way that fosters genuine buy-in at all levels.  

-    Determines opportunities in a data-driven manner and leverages problem-solving best practices to identify and prioritize projects, structure activities, and leads/oversees the facility’s resources in the successful and timely execution of projects.

-    Collaborates with Operational leaders to develop strategies that enable step-change performance of Gibson operations and tracks expectations to deliver results.

-    While working closely with Facility leadership groups and Controllers, expands current KPI’s to include Lean-specific metrics and deploy these throughout the Americas. Is adept at quantifying financial results driven by CI activities.

-    Serves as the overall lead in the execution of large scale, enterprise-level initiatives aimed at enhancing quality, reducing costs, and optimizing delivery across the organization

-    Leads our internal training function, structuring and delivering scalable programs to enhance the skills, practices and collaboration of our team members.  

-    Engages with senior leadership to communicate progress, challenges, and successes of continuous improvement initiatives

-    Collaborates with other functions seamlessly to leverage entire organizations for maximum benefit.

-    Leads overall project pipeline to achieve ongoing cost reduction, delivery and quality improvement goals

-    Works closely with Manufacturing Engineering leadership to align efforts around process improvement.

-    Coaches business leaders and where appropriate trains shop floor management on Lean Management tools and competencies.

Other Duties

-    Can be asked to perform other duties that are reasonable within the area of expertise.

 Required Skills/Abilities     

-    Business and interpersonal skills to energetically and effectively interact at all levels of the organization.

-    Develops, Implements, and Sustains processes where none may exist (Technical, Process, and Cultural Management).

-    Strong analytical and problem-solving skills with the ability to analyze complex data and drive decisions based on insights.

-    Visionary leadership with the ability to inspire and drive change across the organization.

-    Strong project management skills, with the ability to manage multiple initiatives simultaneously.

-    Proven track record of leading enterprise-level initiatives with significant impact.

-    Ability to travel up to 25% domestically to manufacturing and distribution centers.

-    Mastery:  Demonstrated mastery of quality improvement methods such as LEAN & Six Sigma. Lean Six Sigma Black Belt / Master Black Belt or Lean Master certification preferred.

-    Strategic Vision: Ability to develop and execute a strategic vision for continuous improvement across an organization.

-    Influencing: Ability to influence at multiple levels of an organization.

-    Communication: Ability to distill complex ideas, technical concepts, or strategic initiatives into clear, concise, and easily understandable messages tailored to diverse audiences.

-    Change Management: Expertise in leading change initiatives and fostering a culture of continuous improvement.

Education and Experience    

-    Bachelor of Science degree in Engineering is required. Advanced degree is preferred.

-    20+ years of experience in manufacturing environment, with at least 10 years of experience in leading a team of CI professionals and a portfolio of CI projects.

-    Must have experience with the following:

o    Manufacturing processes and production flow

o    Fundamental and established use of Lean Manufacturing techniques, principles and methods as a way of working

o    Project management

o    Change management

o    Financial and Operational metrics for CI.

-    Demonstrated experience establishing and scaling new functions/capabilities.

-    Success leading central functions in a multi-site environment, with a track record of driving change at a site level through partnership and influence.

-    Demonstrated success working in a matrix structure, driving impact through influence. 

-    Demonstrated experience successfully leading and coaching teams through significant change.

-    Preferred: plant leadership experience earlier in career (e.g. plant manager, production manager, supervisor)

-    Influential collaborator to drive and support initiatives/projects with positive Change Management methods and approaches.

-    Extensive knowledge of Lean Manufacturing, Toyota Production System, Kaizen, 5S, and Visual Management

-    Preferred: Experience leading training and development programs in similar environments.

-    Preferred: Experience in high-volume or advanced manufacturing industries (e.g., automotive, aerospace, electronics, or medical devices).

 Work Environment    

Internal:

-    Manufacturing locations

-    Office locations

-    Showroom

-    International locations External:

-    Sales office locations

-    Supplier manufacturing locations

    Travel Requirements    

-    Travel required between internal locations.

Physical Demands    

-    Basic physical stances and actions (sitting, standing, walking)