Senior Material Handling & Lean Operations Expert

Senior Material Handling & Lean Operations Expert

Location: California (client site – on-site / hybrid flexibility depending on project phase)

Type: Contracted (project-based, typically 6–12 months, with strong potential for extension)

Compensation: Competitive, commensurate with experience

Overview

In this hands-on consulting role, you will partner directly with plant leadership and operations teams to optimize material flow, eliminate waste, and deliver rapid, measurable gains in productivity, inventory turns, and on-time delivery.

This is a high-impact opportunity for a lean expert who thrives in repetitive manufacturing environments. You will design and implement best-in-class material handling systems that support high-volume production with minimal product variation—think standardized processes, point-of-use delivery, and flow optimization that directly contribute to EBITDA uplift and operational excellence.

Key Responsibilities

• Lead comprehensive material-handling assessments and redesign material-flow strategies (PFEP, supermarkets, kanban, milk-run/tugger systems, automated guided vehicles, and point-of-use storage) tailored to high-volume, low-mix production.
• Apply deep lean expertise to identify and eliminate waste in internal logistics, line-side replenishment, and warehouse-to-line movement while maintaining or improving safety and quality standards.
• Develop and execute value-creation playbooks focused on material handling, including layout optimization, visual management, standard work for material handlers, and integration with production scheduling.
• Coach and mentor client teams on lean principles, change management, and sustained continuous improvement (Kaizen events, daily management systems, and performance dashboards).
• Collaborate with cross-functional stakeholders (operations, engineering, supply chain, and finance) to quantify improvements, track KPIs (OEE, inventory turns, labor efficiency, dock-to-line time), and deliver 100-day action plans with clear ROI.
• Support broader portfolio operations initiatives, including supply-chain synchronization and cost-reduction programs tied to material handling excellence.

Qualifications & Experience

• Minimum 8 years of hands-on lean practitioner experience in manufacturing operations, with a strong emphasis on material handling and logistics optimization.
• Proven track record in high-volume, low-mix environments (equipment manufacturing, automotive components, appliances, or similar repetitive production settings is highly preferred).
• Deep expertise in lean tools and methodologies: PFEP, value-stream mapping, Kanban, 5S, SMED, pull systems, and material-flow simulation.
• Demonstrated success delivering measurable results (e.g., 20–40% reduction in material-handling labor, 30%+ improvement in inventory turns, or significant OEE gains).
• Prior experience in private-equity-backed or portfolio companies is a strong plus.
• Excellent communication, influence, and project-management skills; able to operate independently and drive change in a fast-paced plant environment.
• Bachelor's degree in Industrial Engineering, Supply Chain, Operations, or related field required; Lean/Six Sigma Black Belt or equivalent certification strongly preferred.
• Willingness to be on-site in California for the duration of the engagement.