• Continuous Improvement (AOS) Manager

    Relocation Available
    Position Type
    Full Time
  • Overview / Job Summary

    Aleris is a global leader in the manufacture and sale of aluminum rolled products, with approximately 14 facilities in three geographically aligned business units in North America, Europe and China. We serve a variety of end-use industries, including aerospace, automotive, defense, building and construction, transportation, packaging, and consumer goods.


    We are seeking to add a talented AOS Manager to our Aleris Operating System (AOS) team at the Richmond, VA plant. The purpose of this role is to lead the implementation, training, teaching, coaching, support, and management of the implementation of a world class continuous improvement system using lean and six sigma techniques in our Richmond, VA facility . The role will require approx. 10% travel to the various sites within North America. This position is a key support and tactical execution role of the cornerstones of the Aleris Operating System – Reliable People(Operations), Reliable Process, Reliable Assets.

    Responsibilities Include

    •Lead the implementation of a world class AOS system: Reliable People (Lean Operations), Reliable Process (Aleris process Control), Reliable Assets (Equipment Reliability).
    •Support the building and development of the AOS system.
    •Drive the cultural transformation within the plant Business Improvement Process role out, support the region during implementation process.
    •Train and develop leaders on lean principles, cultural transformation, A3 development, and the lean leader mindset.
    •Deliver training on a comprehensive world class Lean curriculum for Engineers, technical support, operations, maintenance       and staff throughout the plant.
    •Apply the Aleris Lean activities and tools to the day to day business.
    •Deploy and teach AOS tools at the plant level, including core tools: 5s, A3 Thinking, SMED, RCFA, TWI, Standardized Work, VSM, TPM, APC, Equipment Reliability and Problem Solving.
    •Focus the plant organization towards improvements on safety and reliability (people, process, equipment) through lean techniques and employee engagement.
    •Demonstrate effective team facilitation skills to engage the team and deliver results on time.
    •Drive change within the plant teams to enable Aleris to continuously improve performance, which includes managing the transformation roadmap, and leveraging Information Centers for continuous improvement, and creating a visual workplace.
    •Assist the global and regional leadership in the development of strategic A3s for the business and plants.
    •Provide event follow-up to monitor the progress of planned improvement implementation to assure timely action, appropriate support, and achievement of expected tangible benefits.
    •Lead/facilitate projects and/or events which address plant and region value-at-stake opportunities, helping to drive improvements in all facets of the operations.
    •Owner of the plant AOS roadmap.
    •Lead and participate in AOS and HSE auditing. Drive solution implementation.
    •Identify short-, mid-, and long-term wins that will transform the culture and produce results.
    •Use appropriate measurement, analysis and evaluation methods to accurately identify and document improvements.
    •Coach and develop a problem solving culture at all levels of the organization.
    •Be a leader within the AOS organization – engage the workforce.
    •Ability to communicate across the organization at all levels, from individual contributors to leadership level.
    •Openly and effectively communicate about continuous improvement, build credibility through relationships, and provide leadership to the program.
    •Support the Global and regional AOS organizations in the development of programs/tools/techniques and communication across the Aleris organization.
    •Lead and direct Root Cause Failure Analysis of significant People, Process, Equipment related downtime events; implement permanent corrective actions to mitigate probability of reoccurrence.
    •Lead/facilitate FMEA(Failure Mode Effects Analysis) on all equipment/processes in the plant.
    •Be a resource for operations, maintenance, HSE and supply chain in support of delivering the plant business objectives.
    •Support the regional and global AOS teams – Reliable People, reliable Process, Reliable Equipment.
    •Spend 25% of working time at Gemba (on the plant floor) focusing on employee engagements and teaching the lean concepts.

    Required Qualifications

    •Bachelor’s degree in engineering, manufacturing/operations; or an equivalent level of degree.
    •5+ years of experience facilitating, coaching and implementing TPM, Lean, kaizen/six sigma events and driving lean transformation with proven results and implementations in a manufacturing environment.
    •Six Sigma green belt training/certification; Lean certification required, includes both education and the hands on ability to lead teams and implement improvements.
    •Excellent interpersonal, written, verbal communication skills and organization skills, must be comfortable teaching and presenting to large groups at all levels of the organization.
    •Proven ability to successfully manage cross functional teams, and implement improvement within an established time frame, then sustain improvements.
    •High energy, data driven, and results oriented.
    •Must be proficient in MS Word, MS Excel, MS PowerPoint, MS Project, Oracle, and various analysis tools (minitab, etc).
    •Willingness to travel approximately 10% of the time.


    Preferred Qualifications:
    •Aluminum Casting or Rolling Experience.
    •Process/Technical or Operations experience with a proven track record of lean concepts.
    •CMRP or SMRP certification.
    •Lean Six Sigma Black Belt/Master Black Belt.



    Aleris is an equal opportunity employer and supports diversity in the workplace.  Qualified applications will receive consideration for employment without regard to their race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.  Our HR teams will reach out to the applicants who met the qualifications and most closely aligned with requirements of the positions.


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