Role Overview
The CI Lead drives continuous improvement, eliminates production waste, and optimizes advanced composite manufacturing workflows across our 12,000 m² Slingsby Advanced Composites Facility, based in Kirkbymoorside. Reporting directly to the Head of Production, you will lead Lean manufacturing and Six Sigma initiatives to enhance throughput, reduce budgeted production hours, and ensure compliance with strict aerospace and defence standards. This hands-on role collaborates directly with team leaders, composite laminators, autoclave technicians, and assembly teams to champion a proactive problem-solving culture on the shop floor.
Core Responsibilities
- Process Mapping & Bottleneck Analysis: Map end-to-end composite manufacturing lifecycles—from prepreg layups and autoclave curing to CNC machining and coating—to identify and eliminate production bottlenecks.
- Production Optimisation:
Work alongside the production team and engineering team to streamline the manufacturing processes and or techniques to remove complexities and reduce build times.
- Lean Tool Application: Design and facilitate Kaizen events, 5S workplace visual management, and Value Stream Mapping (VSM) to improve lead times and optimize material handling.
- Root Cause Analysis: Partner with Quality Assurance and NDT technicians to conduct detailed root cause analysis (RCA) on quality deviations, implementing robust corrective actions to maintain AS9100 and NADCAP standards.
- Capacity & Workflow Optimisation: Work alongside production planners to streamline work-in-progress (WIP) tracking and optimize the layout of high-performance assembly cells.
- Culture & Coaching: Deliver continuous improvement training and mentor production teams, embedding a daily problem-solving mindset across the workforce.
Key Metrics & Objectives
- Lead Time Reduction: Accelerate manufacturing cycles for critical aerospace, defence, and marine structures.
- Yield & Waste Improvement: Minimize material scrape rates and rework hours across cleanroom and assembly areas.
- Right First Time (RFT):
Drive standard work adherence to meet on-time delivery (OTD) and quality targets. Qualifications & Experience Requirement Essential Desirable Education Degree or equivalent in Mechanical, Aerospace, or Materials Engineering Lean Six Sigma Green or Black Belt certification Experience 3+ years in manufacturing process improvement Experience within an aerospace or composite environment Technical Skills Process mapping, VSM, 5S, and structured root cause tools Familiarity with NADCAP/AS9100and ERP systems Soft Skills Strong stakeholder management and workshop facilitation Ability to influence and mentor cross-functional production cells
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