Lean Manufacturing & Digitalisation Manager

About the Role

We are seeking an experienced Lean Manufacturing & Digitalisation Manager to lead the continuous improvement and digital transformation agenda across a high-volume manufacturing environment.

This is a hands-on leadership role combining Lean manufacturing, operational excellence, digitalisation, automation, and data-driven improvement. The successful candidate will work closely with Production, Engineering, Quality and IT teams to identify opportunities, implement improvements, and embed a culture of continuous improvement across the manufacturing operation.

Key Responsibilities

Lean & Continuous Improvement Leadership

• Lead and champion the implementation of a comprehensive Lean strategy across all production areas, incorporating 5S, TPM, SMED, Value Stream Mapping, Industrial Engineering, Kanban, and Standard Work.
• Conduct hands-on Gemba walks, process reviews, and data analysis to identify waste, bottlenecks, and opportunities to improve manufacturing flow.
• Lead Kaizen events and continuous improvement workshops, coaching and developing teams to build a sustainable Lean culture.
• Define, implement, and monitor key performance indicators (KPIs) focused on productivity, OEE, scrap reduction, quality, throughput, and cost.
• Develop and implement structured improvement programmes aligned with overall operational and business objectives.

Manufacturing Digitalisation & Industry 4.0

• Identify and implement opportunities to leverage digital technologies and Industry 4.0 solutions to improve manufacturing performance.
• Lead digitalisation projects involving technologies such as IoT, MES/MOM, SCADA, machine connectivity, data analytics, and machine learning.
• Translate manufacturing requirements into practical digital solutions that deliver measurable operational improvements.
• Support the integration of production equipment, systems, and data platforms to improve real-time visibility, decision-making and process control.
• Develop and deploy software and digital solutions for shop-floor applications, including programming, scripting, data processing, and system integration.
• Drive the transition from manual processes and disconnected data towards more automated, connected and data-driven manufacturing.

Quality & Productivity Improvement

• Work closely with Production, Quality and Engineering teams to solve complex manufacturing problems using structured methodologies such as PDCA, 8D, Fishbone and Root Cause Analysis.
• Develop and implement strategies to reduce process variation, improve First Pass Yield (FPY), and increase overall manufacturing efficiency.
• Use manufacturing data and analytics to identify trends, prioritise improvement opportunities and measure the impact of interventions.
• Ensure successful transfer and scale-up of new Lean, digital and manufacturing improvement solutions from pilot through to full production.
• Establish robust standards and controls to ensure improvements are sustained over the long term.

Qualifications & Experience

• Bachelor's degree in Engineering, Industrial Engineering, Manufacturing Engineering, Computer Science, or a related discipline.
• Minimum 5 years' hands-on experience within a high-volume manufacturing or production environment.
• Strong practical understanding of manufacturing processes, production systems, and shop-floor operations.
• Proven experience implementing and sustaining Lean manufacturing and continuous improvement methodologies
• Strong knowledge of tools including 5S, TPM, SMED, VSM, Kaizen, Standard Work, Kanban, and OEE.
• Minimum 3 years' experience delivering manufacturing digitalisation or Industry 4.0 projects.
• Experience with technologies such as MES, SCADA, IoT, machine connectivity, manufacturing data analytics, or similar digital manufacturing systems.
• Demonstrated proficiency in at least one modern programming language such as Python, C# or Java, or equivalent scripting experience.
• Experience in data processing, system integration, automation, or development of shop-floor digital solutions.

Core Competencies

• Production Acumen: Deep, practical understanding of manufacturing operations with the ability to work effectively and credibly on the production floor.
• Lean Leadership: Proven ability to lead continuous improvement programmes and embed Lean principles across an organisation.
• Digital & Technical Capability: Ability to bridge manufacturing operations with digital technologies and translate technical opportunities into practical business solutions.
• Leadership: Strong capability to lead cross-functional teams, influence stakeholders, and coach others in Lean and digital manufacturing practices.
• Problem-Solving: Excellent analytical and structured problem-solving skills, with a strong focus on root cause analysis and data-driven decision-making.
• Communication: Ability to communicate complex technical, digital and process concepts effectively at all organisational levels, from operators to senior leadership.
• Innovation & Adaptability: Comfortable working at the intersection of traditional manufacturing excellence, automation, and emerging digital technologies.

For further information on this Lean Manufacturing & Digitalisation Manager role in Galway please contact Caroline Kingston on +353 868395531 or email caroline@hero.ie Check out all our open jobs on our HERO Recruitment website – https://www.hero.ie/.

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