Continuous Improvement Manager


Manufacturing and tooling
Johor Bahru - Malaysia


We are looking to hire a Continuous Improvement Manager to join our team in Johor


  • Leading a team of CI Specialists and Data Engineers to achieve Continuous Improvement across the various functions of the factory
  • Applying knowledge of continuous process improvement for business and operational processes within a high volume manufacturing environment.
  • Assist and lead project and change management efforts plus maintain responsibility for process improvement projects.
  • Support the execution of continuous process improvement projects and implementation efforts.
  • Develop expertise in Lean Six Sigma, Theory of Constraints, and business process reengineering.
  • Work on process improvement and data analysis, including Six Sigma methodologies. 
  • Plan and facilitate structured improvement activities.
  • Drive lean certification across the team
  • Plan, Develop, Facilitate and Effectively Implement Lean Activities to drive Excellence throughout
  • Drive continuous improvement thru 4 levers - Visual Control Systems, Management Routines, problem Solving Workshops and Key Performance Indicators.
  • To provide technical knowledge and leadership for implementation of Lean Manufacturing principle throughout the organization.
  • Helps the plant to constantly improve in Quality, Service, Empowerment, Supply chain, Efficiency and Capex utilization through rigorous application of the standard Lean tools.
  • Drives cultural change to help management adopting lean thinking, shop floor attitude (where the action takes place), fosters people development and empowerment.
  • Visual Workplace Management. Promote lean cultural transformation, 5S program, flash meeting and visual factory.
  • Set up Effective Suggestion System.
  • Team Based Organization
LEAN SUPPLY CHAIN by design and implement an optimized material flow for the entire plants
  • Level customer demand in the production plan @ Implementing master production schedule.
  • Pull production through the flow@Implement Kanban System, Small Train, Leveling and Shop Stock.
  • Reduce lead-time by reducing production batches @ Reduce changeover duration thru Single Minutes Exchange of Dies (SMED)
  • Level supplier orders @ Milk Run, Supermarket & Just in Time principles.
LEAN SAFETY. Passion for driving environmental, health & safety improvements with 'zero incidents' mentality.
  • Implement Safety Barometer to correct people wrong Safety behaviour.
  • Accident 8D structured problem-solving methodology to analyse the root causes of a safety accident, based on 8 steps road map.
  • Implement Lock Out Tag Out (LOTO) system.
  • Introduce Quality Wall inspection to protect Customers until the process is proven capable.
  • Go 1st Part and 1st Defect Stop to have a fair chance to produce good parts from the production start.
  • Red Bin review and QRQC workshop to quickly react and resolve problems at the source.
  • Conduct an 8-D on every customer complaint to improve efficiency.
  • Rigorous method to seek for manufacturing productivity improvements using Hoshin Workshop approach.
  • Increase Overall Equipment Efficiency (OEE) and Total Effective Equipment Productivity (TEEP) thru Total Productive Maintenance by eradicating machine and tool Breakdowns and Micro-stops.
  • Helps tooling teams to manage the Spare Parts Ordering and Analyzing by introducing Spare part Management system.
  • Design and implement Kamashibai Board, a visual board for preventive maintenance.
  • Cardboard Engineering workshop aiming to optimize a new assembly equipment design toward lean process design principles – Mix Flexibility, Flexible Manpower Line and Minimum Technical Solution.
  • Utilize Lean Manufacturing Concepts for all plant materials management activities (material and information flows)
  • Utilize Continuous Improvement (Kaizen) techniques, initiate process improvements, cycle time reductions, cost reductions and other activities aimed at reducing/eliminating non-value-added activities in the process.Build relationships across all levels to understand ongoing operational issues and lead improvement andsustainability efforts.
  • Study, evaluate and apply current trends manufacturing practices
  • Lead,coach and manage multiple lean workshop simultaneously
  • Think out of the box and to pioneer on new frontier to search for continuous improvement using lean approach across the manufacturing plant.
  • Lead value stream mapping exercises to identify and document opportunities to improve the business (current and future state). Develop and execute projects plans in order to achieve the future state internal and external.
  • Manage and lead employees performing improvement activities including a group of CI Specialists and Data Engineers, ensuring that the activity is tied back business and technical strategies, goals and objectives.
  • Utilize training techniques and leverage own expertise to serve as a primary instructor for lean training.
  • Influence,collaborate and communicate with all employees and management to drive the indoctrination of these principles and methods into the culture.
  • Work closely and interface with all functional areas i.e. Operations, Purchasing, Planning, Finance, Human Resources and regional / global business excellence team.
  • Deploy / share best practices across teams thru “Lean Excellence Day”.
  • Maintain and update publicity of Lean notice board, Lean Gallery with (i) Monthly Kaizen submission, Yearly APU winners; (ii) Lean Articles and (iii) Lean Training & Workshop and etc.
  • Deploy, monitor and control Key Performance Indicators (KPI).


  • Degree in Engineering, Operations Management, Business or other related field of study.
  • 5-10 years’ experience in Lean Manufacturing and Six Sigma preferable
  • Holder of Lean Six Sigma Master Black Belt
  • A formal Project Management qualification is desirable but not essential
  • Incumbent to have manufacturing or product experience.
  • Proven experience of leading successful teams and managing projects on time, to specification and within cost constraints
  • Knowledge and understanding of manufacturing techniques and limitations is desirable.


Dyson Malaysia monitors the market to ensure we offer competitive salaries, management bonuses and pension contributions. Beyond that, you’ll enjoy generous leave and medical care and insurance. But financial benefits are only the start of a career at Dyson. Leadership support and new opportunities abound, driven by regular dialogue and international training. And with a vibrant culture, the latest devices and a relaxed dress code reflecting our engineering spirit, it’s an exciting team environment geared to progress, innovation and realising ambition.

Posted: 14 August 2019