Lead Lean Manufacturing Specialist
manufacturing › Lean Manufacturing · S5 — S5 — Principal Support Specialist · Support
Senior individual contributor who drives lean manufacturing methods and design-for-manufacture practices across product lines to speed time to market.
Median pay · United States · annual
$62,559 USD
▲ +62.4% vs S1 on this ladder
Typical range ()
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What this role is
Senior individual contributor who drives lean manufacturing methods and design-for-manufacture practices across product lines to speed time to market. At the Principal Support Specialist (S5) level, the role owns function-wide support practice, program-level and systemic support problems, and drives support strategy across the function. Subject-matter authority; shapes the practice.
What this level does
- Contribute to the creation of new plant data-collection, audit, and sustainment procedures for the lean system where none exist, and standardize them for others to follow
- Develop and maintain the plant's library of standard work-measurement templates, 5S/TPM audit criteria, and Kanban sizing methods as the recognized specialist
- Facilitate and mentor peers and engineers on lean-toolkit execution, providing guidance that resolves complex, cross-area sustainment problems
- Design measurement and error-proofing techniques for the most complex value streams, translating engineering intent into repeatable floor-level procedures
- Act as working lead and facilitator for the plant's continuous-improvement audit program, setting the cadence and coaching data owners across areas
- Knowledge applied
- Highly skilled specialist in the plant's lean-system procedures; contributes to creating new measurement, audit, and sustainment methods.
- Complexity & problem solving
- Develops procedures and techniques; resolves complex, cross-area sustainment and measurement problems.
- Collaboration & interaction
- Acts as working lead/facilitator; provides guidance to and influences peers and engineers on lean-toolkit execution.
- Typical experience
- 6+ years; expert in lean-support methods and the plant's internal lean system.
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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