Advanced Lean Manufacturing Engineer
manufacturing › Lean Manufacturing · S4 — S4 — Lead Support Specialist · Support
An experienced individual contributor who applies advanced lean methods to streamline product development and manufacturing ramp-up.
Median pay · United States · annual
$58,202 USD
▲ +51.1% vs S1 on this ladder
Typical range ()
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What this role is
An experienced individual contributor who applies advanced lean methods to streamline product development and manufacturing ramp-up. At the Lead Support Specialist (S4) level, the role owns team process and quality, cross-case patterns and process gaps, and drives team-level quality and efficiency. Mentors and coordinates the support team.
What this level does
- Adapt lean measurement and audit procedures for unprecedented situations — new product introductions, unfamiliar equipment moves, or lines with no existing standard work to measure against
- Resolve conflicting or ambiguous shop-floor data by determining a fit-for-purpose measurement method and defending the approach to engineering and operations
- Act as working lead for less-experienced support staff during multi-area Kaizen and Value Stream events, assigning data-collection roles and reviewing their outputs
- Recommend and pilot new error-proofing and visual-management approaches when existing standards do not fit the situation, tracking results
- Serve as the plant's go-to for the SPS/internal lean-system standards, interpreting them for cases the written procedure does not cover
- Knowledge applied
- Extensive knowledge of the lean system and its administration, enough to adapt measurement and audit methods in unfamiliar or unprecedented situations.
- Complexity & problem solving
- Understands the implications of data and recommends new solutions; resolves conflicts in ambiguous floor situations resourcefully.
- Collaboration & interaction
- May informally guide and review the work of less-experienced support staff during multi-area events; go-to for internal lean-system standards.
- Typical experience
- 4–6 years; advanced lean-support experience.
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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