Director 1 Process Excellence NEW

Huntsville, Alabama
Northrop Grumman
RELOCATION ASSISTANCE: Relocation assistance may be available

CLEARANCE REQUIRED FOR START: No

CLEARANCE TYPE: None

TRAVEL: Yes, 50% of the Time Description

At Northrop Grumman, our employees have incredible opportunities to work on revolutionary systems that impact people’s lives around the world today, and for generations to come. Our pioneering and inventive spirit has enabled us to be at the forefront of many technological advancements in our nation’s history – from the first flight across the Atlantic Ocean, to stealth bombers, to landing on the moon. We look for people who have bold new ideas, courage and a pioneering spirit to join forces to invent the future, and have fun along the way. Our culture thrives on intellectual curiosity, cognitive diversity and bringing your whole self to work – and we have an insatiable drive to do what others think is impossible. Our employees are not only part of history, they’re making history.

The Director 1 Process Excellence leader is the senior champion for Manufacturing Engineering (ME), Industrial Engineering (IE), and Continuous Improvement (CI), specifically Lean Manufacturing across our production network. Reporting to the VP of Quality, Manufacturing and Infrastructure, this role develops and executes the engineering driven, lean focused roadmap that delivers higher quality, higher productivity, lower cost, and safer workplaces. The incumbent works hand-in-hand with site, division and sector manufacturing, product development, quality, supply chain, and IT across several sites to embed lean principles and manufacturing / Industrial engineering best practices into every step of the value stream-from concept to high volume production.

Sector QM&I Director, Process Excellence responsibilities:

Manufacturing Engineering

• Process Design & Scale Up – Lead the design, qualification (IQ/OQ/PQ) and scale up of manufacturing processes, equipment, fixtures, and tooling for new products and product revisions.
• Technology Transfer – Own the NPI hand over from R&D to the shop floor, ensuring cost, cycle time, and yield targets are met.
• Equipment Optimization – Drive retrofits, automation upgrades, and line redesigns that improve OEE and reduce change over time (SMED).
• Standardization – Create and maintain robust work instructions, SOPs, and process specifications that are the “single source of truth” for production.

Industrial Engineering

• Capacity Planning & Line Balancing – Perform takt time analysis, line balancing, and capacity modeling to meet forecast demand while minimizing labor and equipment bottlenecks.
• Facility Layout & Flow – Design/optimize plant layouts, cellular manufacturing cells, and material flow (value stream mapping) for maximum efficiency and minimal handling.
• Simulation & Digital Twins – Use discrete event simulation, digital twin tools, and data analytics to evaluate “what if” scenarios before physical changes are made.
• Work Study & Motion Analysis – Conduct time studies, method studies, and ergonomic assessments to set standard labor times and reduce fatigue.

Lean Manufacturing (Continuous Improvement)

• Develop and own the CI strategy – Create a 3 year Lean transformation roadmap that aligns with corporate goals and secures the required budget and resources.
• Lead CI governance – Chair the Continuous Improvement Steering Committee, establish Kaizen teams, and enforce a standardized project charter and audit cadence across all sites.
• Drive value stream analysis and Kaizen – Oversee end to end value stream mapping, prioritize rapid improvement events, and ensure that each event delivers measurable performance gains.
• Define, track, and report KPIs – Maintain the CI scorecard (OEE, lead time, waste rate, cost per unit, ROI, training penetration, etc.) and present results to senior leadership on a monthly basis.
• Build Lean capabilities – Design and roll out a Lean Academy (Yellow, Green, Black Belt), mentor emerging CI champions, and sustain a pipeline of certified practitioners.
• Implement change management programs – Deploy visual management, daily management systems, and communication campaigns that embed a continuous improvement culture throughout the organization.
• Manage ROI and financial oversight – Develop business cases for CI projects, track benefits versus costs, and control the CI budget (including external consulting and training spend).

People & Culture

• Recruit, develop, and retain a high performing ME/IE/CI team (engineers, analysts, facilitators).
• Mentor plant leaders and front line teams in lean thinking, data driven decision making, and change management.
• Create a “continuous improvement as a habit” culture measured by participation rates and sustained gains.

Data, Metrics & Digital Enablement

• Define the KPI set for ME, IE, and Lean (OEE, SCRAP, First Pass Yield, Labor Hours per Unit, Change over Time).
• Integrate MES/ERP data streams into real time dashboards; ensure data integrity for decision making.
• Champion the use of advanced analytics (statistical process control, predictive maintenance, AI) to pre empt losses.

Financial Stewardship

• Build business cases (ROI, payback) for all engineering and lean projects; track actual savings vs. target.
• Partner with Finance to embed process costs into product costing and margin analysis.

Safety, Quality & Compliance

• Embed EHS and Quality requirements (ISO/TS, GMP, IATF) into every process design and lean activity.
• Conduct risk assessments (PFMEA, Process Hazard Analysis) and drive corrective actions promptly.

The successful candidate will possess the following competencies and skills:

• Deep knowledge of Manufacturing Engineering: process design, automation, tooling, and equipment qualification.
• Strong Industrial Engineering fundamentals: line balancing, capacity planning, layout design, simulation.
• Mastery of Lean Manufacturing (Certified Lean Expert or equivalent).
• Advanced statistical analysis (Minitab, JMP, R, Python) and data visualization (Power BI, Tableau).
• Ability to turn raw production data into actionable improvement plans.
• Coaching/mentoring skillset to develop engineering and shop floor talent.
• Experience delivering multi site engineering or lean programs on time and within budget
• Clear, concise written and verbal communication; capable of presenting technical concepts to executives and frontline workers alike.
• Understanding of cost structures, margin drivers, and supply chain dynamics in a high mix, high volume manufacturing environment.
• Curiosity for emerging manufacturing technologies (robotics, additive manufacturing, AI/ML) and a track record of scaling them.

Basic Qualifications:

• Bachelor’s degree with 10 plus years of relevant experience OR Master’s degree with 8 plus years of relevant experience
• 10+ years progressive experience in manufacturing/industrial engineering.
• At least 5 years in a leadership role focused on lean/continuous improvement.
• Certified Lean Expert
• Proven ability to lead cross functional, matrixed teams and to influence senior leadership without direct authority.
• Proven ability to build and maintain high performing teams.
• Proven ability to take ownership and be accountable with an “owners” mindset.
• Strong interpersonal skills, an exceptional self-starter attitude, and the ability to produce in a dynamic, fast-paced environment.
• Strong business/financial acumen, keen organizational skills, and excellent problem-solving ability.
• Ability to obtain and maintain a security clearance up to Top Secret

Preferred Qualifications:

• Master’s degree (MBA, Engineering Management, or related)
• Experience leading global, multi plant engineering and lean programs.
• Prior exposure to Industry 4.0 initiatives (IoT, digital twins).
• Lean Six Sigma Black Belt or Master Black Belt; PMP; APICS CPIM/CSCP.
• Active Top Secret Clearance

Primary Level Salary Range: $176,100.00 – $305,900.00

The above salary range represents a general guideline; however, Northrop Grumman considers a number of factors when determining base salary offers such as the scope and responsibilities of the position and the candidate’s experience, education, skills and current market conditions.

Depending on the position, employees may be eligible for overtime, shift differential, and a discretionary bonus in addition to base pay. Annual bonuses are designed to reward individual contributions as well as allow employees to share in company results. Employees in Vice President or Director positions may be eligible for Long Term Incentives. In addition, Northrop Grumman provides a variety of benefits including health insurance coverage, life and disability insurance, savings plan, Company paid holidays and paid time off (PTO) for vacation and/or personal business.

The application period for the job is estimated to be 20 days from the job posting date. However, this timeline may be shortened or extended depending on business needs and the availability of qualified candidates.

Northrop Grumman is an Equal Opportunity Employer, making decisions without regard to race, color, religion, creed, sex, sexual orientation, gender identity, marital status, national origin, age, veteran status, disability, or any other protected class . click apply for full job details