Director of Lean Manufacturing: Top Recruiters in Birmingham, Alabama
The Birmingham Advanced Manufacturing Market
Birmingham's manufacturing sector is anchored by Nucor's innovative steel mini-mill operations, Mercedes-Benz US International's SUV production facility, and Honda's Alabama assembly plant, creating demand for world-class automotive and steel manufacturing executives.
About This Role
The Director of Lean Manufacturing leads the implementation of lean production systems across manufacturing facilities, converting traditional push-based production to pull-based, flow-oriented systems that minimize lead time, reduce inventory, and improve quality through built-in error prevention. This director drives waste elimination and standard work development at the shop floor level.
Key Responsibilities
- Lead lean transformation of manufacturing operations from traditional batch production to lean pull systems
- Design and implement value stream maps, future-state designs, and transformation roadmaps for each facility
- Implement standard work, visual management, 5S, and daily management systems on the shop floor
- Lead takt time analysis, line balancing, and production cell design to optimize flow and labor utilization
- Deploy pull systems including kanban, supermarkets, and heijunka leveling for production planning
- Lead error-proofing (poka-yoke) and quick changeover (SMED) programs to reduce defects and setup time
- Train and develop lean practitioners at all levels from hourly associates to plant management
- Measure lean adoption through lean maturity assessments and track progress toward lean enterprise goals
- Lead problem-solving culture development using A3 thinking, 5-Why analysis, and PDCA methodology
- Engage senior leadership in lean leadership behaviors including gemba walks and respect for people practices
Leading Employers in Birmingham
The Advanced Manufacturing talent pool in Birmingham is shaped by movement between these anchor employers and their tier-one supplier base:
Required Experience & Background
- 10+ years in lean manufacturing with demonstrated expertise in Toyota Production System or equivalent
- Six Sigma Black Belt and Lean Expert certification preferred
- Demonstrated experience leading lean transformations across multiple manufacturing facilities
- Track record of significant lead time reduction, inventory reduction, and flow improvement results
- Hands-on shop floor experience with direct involvement in standard work development and kaizen execution
- Training and coaching skills with experience developing lean practitioners across organizational levels
Core Leadership Competencies
- Lean System Expertise: Comprehensive knowledge of TPS/lean production system principles and tools
- Shop Floor Leadership: Ability to work at the gemba and drive change at the point of value creation
- Standard Work Discipline: Commitment to developing and sustaining standard work as the foundation for improvement
- Visual Management: Skill in designing workplace visual controls that make problems immediately visible
- Coaching Culture: Ability to develop lean thinkers at all levels through hands-on coaching and teaching
Regulatory & Compliance Context
Lean transformation activities must comply with OSHA safety regulations, particularly when changing workflow, production cell layout, or materials handling methods. Process changes affecting product quality must follow ISO 9001 change management requirements, IATF 16949 PPAP validation for automotive suppliers, or AS9100 engineering change processes for aerospace products.
Compensation Benchmarks for Birmingham, AL
Nexoval Search Partners' Approach in Birmingham
Nexoval Search Partners's dedicated Advanced Manufacturing practice maintains active relationships with the executive talent community across Birmingham and the broader Alabama market. Our consultants conduct thorough market mapping of available passive and active candidates across the region's leading employers, from established industry leaders to innovative growth companies. Every engagement includes confidential outreach, rigorous competency-based assessment, and candidate presentation within 45 to 60 days of engagement launch. Nexoval Search Partners's retained search model and one-year replacement guarantee ensure every executive we place in Birmingham, Alabama delivers long-term organizational value.