Scope of Work
• Responsible for leading Lean initiatives across all helmet production areas: shell manufacturing, EPS liner forming, painting, assembly, testing, and packaging.
• Report directly to the General Manager and interface with Global Lean or CI teams if part of a group.
• Drive performance improvements with clear ROI in cycle time, material usage, labour productivity, and safety compliance.
• Influence process design and factory layout to ensure flow, flexibility, and scalability of helmet production operations.
• Perform and lead the team under ISO19001, ISO14001 and other standard related including Safety regulations.
• Perform other function assigned by General Manager
Key accountabilities
1. Lean Program Development
• Design and implement a Lean roadmap specifically aligned with crash helmet production workflows, including molding, painting, assembly, and testing
● Eliminate waste in processes such as helmet shell forming, vent integration, padding installation, and packaging.
2. Continuous Improvement Leadership
● Lead continuous improvement events (Kaizen) focusing on safety, quality, delivery, and cost (SQDC).
● Apply SMED to reduce changeover times between helmet models and colours.
3. Standardization and Training
● Develop and enforce standard work across all helmet production lines.
● Train employees at all levels in Lean tools with a focus on defect prevention, cycle time reduction, and layout
optimization.
4. Data-Driven Improvements
● Analyze production metrics (OEE, first-pass yield, scrap rate) to identify bottlenecks or inefficiencies.
● Work closely with Quality to reduce warranty claims, rework, and customer complaints.
5. Cross-Functional Collaboration
● Collaborate with R&D, Engineering, and Maintenance teams to ensure design-for-manufacturing (DFM) principles are embedded early.
● Support production during new product introductions (NPI) and model transitions.
6. Sustainability and Culture
● Foster a Lean culture where operators actively contribute to daily improvements.
● Implement visual management and daily accountability boards on the shop floor.
Advanced Composite System Ltd.
