Senior Lean Manufacturing Technician
manufacturing › Lean Manufacturing · S3 — S3 — Senior Support Specialist · Support
Experienced technician who applies lean tools and design-for-manufacture practices to improve production flow and shorten time to market.
Median pay · United States · annual
$51,142 USD
▲ +32.8% vs S1 on this ladder
Typical range ()
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What this role is
Experienced technician who applies lean tools and design-for-manufacture practices to improve production flow and shorten time to market. At the Senior Support Specialist (S3) level, the role owns escalated / complex cases, complex or non-standard cases, and drives resolution quality on the team's hardest cases. Guides junior support informally.
What this level does
- Independently plan and execute time-standard studies for non-routine or mixed-model lines, using judgment to decide observation counts and how to handle process variation
- Lead problem-solving data-gathering on quality and productivity issues, tracing a defect back through station data to a probable cause for engineering confirmation
- Facilitate the routine 5S / visual-management / Kanban sustainment program across the plant without daily instruction, prioritizing which areas need intervention
- Document proposed method and layout adjustments and recommend error-proofing opportunities where the data shows recurring waste
- Coordinate the logistics and data capture of Kaizen workshops, adapting the standard agenda to the specific process being improved
- Knowledge applied
- Detailed knowledge of lean procedures sufficient to run non-routine studies and sustainment work independently, using judgment on measurement approach.
- Complexity & problem solving
- Makes judgments on moderately difficult tasks — mixed-model lines, defect traceback — with little daily instruction.
- Collaboration & interaction
- Coordinates data-collection tasks during Kaizen events and audits; substantial procedural understanding, no people-leadership.
- Typical experience
- 2–4 years; skilled in lean-support routines across the plant.
Skills at this level
- Work Measurement & Time Studies
- — Measures Takt time, cycle time, changeover (SMED) duration, and lot-size requirements at the station using standardized observation methods, and compiles the data to support line balancing and Lean-line expansion.
- 5S & Visual Workplace Sustainment
- — Audits and maintains 5S workplace organization, visual-management boards, and floor markings against the documented standard, logging drift and restoring conditions on the shop floor.
- Kanban & Material Flow Upkeep
- — Maintains Kanban cards and signals, verifies pull-system replenishment quantities, and captures material-flow data used to keep line flow aligned to Lean layout standards.
- Error-Proofing (Poka-Yoke) Verification
- — Confirms mistake-proofing devices are present and functioning at each station, logs device failures, and identifies recurring-waste points where new error-proofing is warranted.
- TPM Audit Support
- — Performs Total Productive Maintenance audit walks, records equipment-condition and autonomous-maintenance findings against the checklist, and tracks status across audit cycles.
- Kaizen Event Logistics & Data Capture
- — Sets up workshops targeted at changeovers, 5S, Value Stream, and workplace organization by staging materials and boards, and records before/after measurements during the event.
- Value Stream Data Collection
- — Gathers station-level and process-flow data needed to build and update value stream maps, reconciling observations against existing standard work.
- Manufacturing Data Entry (ERP/MES)
- — Enters time-study, audit, and throughput measurements into the plant's ERP/MES spreadsheets and reports so engineering analysis works from accurate floor data.
- Shop-Floor Problem-Solving Support
- — Supports structured problem-solving on quality and productivity issues by tracing defects back through station data to isolate a probable cause for engineering confirmation.
- Internal Lean-System Standards (SPS)
- — Interprets and applies the plant's proprietary lean production-system standards, and at senior levels helps create new floor-level procedures where written standards do not yet cover a situation.
- Quality-Standards Compliance
- — Keeps data-collection and housekeeping activities aligned with ISO quality standards and safety/environmental requirements applicable to the work area.
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As of · 2026-07-30
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