Continuous Improvement Manager - MBG

Key Responsibilities

• Own plant-wide COPQ reduction strategy, including: Baseline accuracy, internal failures (scrap, rework, repair hours), external failures (warranty, dealer claims, field issues), extended appraisal costs (inspection inefficiencies).
• Align with MBI Quality initiatives by co-establishing brand/site baseline COPQ metrics and drive year-over-year reduction targets.
• Lead structured problem-solving activities by using: A3 thinking, Root Cause Analysis (RCA), 8D / DMAIC methodologies, Facilitate cross-functional problem-solving activities (workshops, coaching, training, etc.) on top external (warranty) and internal (plant losses), including: Inspection, Rework, Gelcoat and cosmetic defects, Upholstery rework, Electrical and functional system failures.
• Ensure permanent corrective actions with validation, standardization, and follow-up audits.
• Create capability across teams to solve problems at the root cause—not symptoms.
• Create transparency through COPQ dashboards and integrate into daily management.

Operational Excellence in Premium Boat Manufacturing

• Lead continuous improvement initiatives across key brand/site production processes: Parts and component assembly, Fiberglass hull/deck layup, Upholstery and interior finishing, Rigging (electrical, ballast, surf systems), Final assembly, detailing, and water testing.
• Improve flow and reduce bottlenecks in large-product, station-based assembly.
• Optimize takt alignment and line balancing in high-mix production.

Craftsmanship + Efficiency

• Implement Lean tools while protecting Malibu’s premium quality standards: Standard Work with built-in quality controls, Visual Management for production and quality performance, 5S in high-visibility, finish-critical areas, Layered Process Audits (LPA).
• Optimal setup and controls leading to defect and COPQ reduction.
• Target waste reduction in: Resin and composite material usage, Rework loops and repair stations, Labor inefficiencies driven by variation.

Quality & Brand Protection

• Partner with MBI Quality to protect the premium brand reputation.
• Improve first-pass yield (FPY), reduce defects per unit (DPU), and reduce defect escape rates.
• Drive mistake-proofing (poka-yoke) in critical systems affecting: Safety, Performance, Customer-visible quality.
• Translate dealer feedback and warranty trends into actionable improvement plans.
• Prioritize improvements that enhance the on-the-water customer experience.

Performance Management & Visual Systems

• Establish plant-wide SQDC and COPQ visual management systems.
• Track and drive key KPIs: COPQ as % of sales, Rework hours per boat, FPY and/or DPU, Warranty cost per unit, Throughput and on-time delivery.
• Lead daily Gemba and tiered accountability meetings.

Production Scaling Support

• Support ramp-up/down aligned to demand cycles.
• Improve workforce flexibility via cross-training and standard work.
• Maintain quality discipline during high-volume peak periods.

Culture & Capability Building

• Support growth of problem-solving capability at all levels of the organization.
• Coach supervisors and team leaders on structured CI and defect elimination.
• Drive accountability for “build it right the first time” mindset.
• Increase employee engagement in kaizen and continuous improvement.

Project Leadership & Execution

• Lead a pipeline of CI projects with measurable impact on COPQ and operational performance.
• Partner with Engineering, Production, Quality, and Supply Chain.
• Ensure sustainability through standard work, audits, and leader standard work.