Continuous Improvement / Lean Manager

In the heart of Central Ohio, Illuminate USA is transforming solar panel manufacturing from our cutting-edge facility in Pataskala. As a new standalone joint venture established by two global leaders in renewable energy, we’ve rapidly grown to over 1,500 associates and are now fully operational in our 1.1 million-square-foot factory. Our vision is to establish one of the largest solar panel manufacturing operations in the Western Hemisphere.

This is an exciting time to join Illuminate USA as we continue to grow and innovate. We’re not just building solar panels—we’re building a team of dedicated, passionate associates eager to make a real impact. If you’re looking to be part of a collaborative, people-focused, and forward-thinking workplace, we want to hear from you!

We offer competitive pay, comprehensive benefits, and continuous opportunities for career growth. Come join us on this journey to create a brighter, more sustainable future in the Columbus area.

Illuminate USA is seeking a results-driven Continuous Improvement / Lean Manager to lead and accelerate factory-wide improvement initiatives across Safety, Quality, Delivery, Cost, and Productivity. This leader will drive structured problem solving, standard work deployment, Kaizen execution, and Lean culture development across the manufacturing organization. This role requires strong facilitation skills, data-driven decision making, and the ability to influence across functions including Production, Equipment Engineering, Maintenance, Process Engineering, Quality, Supply Chain, and EHS.

Key Responsibilities

Lead plant-level Lean transformation efforts including waste elimination, flow improvement, and productivity improvements.

Drive deployment and maturity of Lean tools:

5S, Standard Work, Visual Management, A3, Kaizen, Value Stream Mapping (VSM), SMED, TPM, and Daily Management Systems (DMS).

Own the CI roadmap including priorities, timeline, resource alignment, and measurable business outcomes.

Facilitate and lead Kaizen events, rapid improvement workshops, and cross-functional problem-solving sessions.

Coach teams on structured root cause methods including 5-Why, Fishbone, 8D, Pareto, and FMEA alignment.

Ensure countermeasures are implemented sustainably (verified effectiveness, control plan ownership, audit cadence).

Partner with leadership to establish and drive performance improvement in:

OEE / Availability, Yield, Throughput, Scrap PPM, Cycle Time, Labor Efficiency, Downtime Reduction

Build and maintain weekly/monthly reporting and review cadence including action tracking, escalations, and closure discipline.

Support tiered meeting structure and daily accountability routines to improve execution consistency.

Lead creation and deployment of standardized processes across shifts and workstations.

Audit and sustain improvements through layered process audits (LPA), leader standard work, and sustainment plans.

Train, coach, and develop leaders and frontline teams to build CI capability and ownership.

Lead CI initiatives tied to equipment reliability, line balancing, changeover reduction, material flow, and defect containment.

Partner with Engineering and Maintenance to improve uptime through TPM elements and defect prevention.

Support new line ramp, retrofits, and operational readiness activities by ensuring Lean principles are embedded.

Required Qualifications

Bachelor’s degree in Engineering, Business, Operations, Industrial Engineering, or related field (or equivalent experience)

7+ years of experience in Manufacturing, Operations, or Continuous Improvement roles

Demonstrated success driving measurable improvements in a high-volume manufacturing environment

Strong working knowledge of Lean / CI methods and structured problem-solving

Proven ability to lead cross-functional teams without direct authority

Preferred Qualifications

Lean certification (Lean Six Sigma Green Belt/Black Belt preferred)

Experience in advanced manufacturing (automation-heavy, high-mix or high-volume preferred)

Experience implementing Daily Management Systems (DMS) and tiered accountability

Background in KPI systems (OEE, yield, throughput, cost tracking, scrap reduction)

Physical Requirements

Ability to sit or stand for extended periods of time

Occasional walking within office and manufacturing areas

Ability to lift up to 25 lbs on an occasional basis

Ability to view screens, read documents, and communicate effectively

At Illuminate USA, we are committed to fostering an inclusive and diverse workplace. We proudly embrace equal opportunity for all, ensuring that all qualified applicants are considered for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, or any other characteristic protected by law. Your unique background and experiences are valued here, as we believe they strengthen our team and drive our mission forward.

Illuminate is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.

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