Continuous Improvement Manager

Job Overview

Our client, an Athlone-based company specialising in the commercial vehicle industry, is seeking an experienced and dynamic Continuous Improvement Manager to join their team.

The Continuous Improvement Manager is responsible for identifying inefficiencies, eliminating operational waste, and driving continuous improvement across all workshop bays, CVRT testing lines, parts logistics, and front-of-house service operations.

The successful candidate will take ownership of continuous improvement initiatives across the business, working closely with workshop, parts, CVRT, and service teams to improve operational efficiency, reduce vehicle downtime and rework, maximise resource utilisation, and embed a sustainable Lean culture.

Key Responsibilities

1. Workshop & Flow Optimisation

· Map and analyse end-to-end vehicle service workflows to identify bottlenecks, eliminate operational waste, and reduce vehicle off-road (VOR) time.

· Develop, implement, and standardise technician Standard Operating Procedures for routine maintenance, heavy commercial vehicle repairs, and pre-CVRT inspections.

· Implement and maintain 5S methodology across repair bays, specialist tooling storage, diagnostic stations, and the main workshop floor.

· Work closely with Workshop Foremen to optimise job scheduling, balance technician workloads, improve workflow, and maximise bay utilisation and cycle times.

2. Parts Department & Supply Chain Alignment

· Partner with the Parts Manager to implement Kanban/pull systems, ensuring high-turnover Renault Trucks service items and CVRT consumables are readily available when required.

· Identify and eliminate unnecessary movement, transit, and retrieval time between the parts counter, storage areas, and repair bays.

· Improve parts availability and coordination between the Parts and Workshop teams to minimise delays and vehicle downtime.

3. CVRT Testing & Compliance Streamlining

· Analyse throughput across light and heavy CVRT testing lanes to minimise queueing, balance appointment scheduling, and manage periods of peak demand.

· Identify opportunities to streamline the CVRT intake, testing, and rectification process.

· Introduce data tracking around first-time pass rates and use findings to identify recurring defects and feed preventative actions back into workshop operations.

4. Culture, Training & Kaizen Execution

· Lead cross-functional Kaizen/Continuous Improvement initiatives targeting identified operational pain points, including job check-in delays, parts waiting times, and warranty administration.

· Coach team leads, master technicians, service reception staff, and relevant personnel in structured root-cause problem-solving techniques, including Fishbone, 5 Whys, and PDCA.

· Develop a culture of employee involvement, encouraging teams to identify inefficiencies and contribute practical improvement ideas.

· Introduce and maintain Visual Management across workshop operations, using performance boards to communicate key metrics including WIP, TAT, First-Time-Right, and bay efficiency.

5. Data Analytics & KPI Reporting

· Establish, track, and regularly review key operational performance indicators.

· Use operational data to identify trends, prioritise improvement opportunities, and measure the impact of CI initiatives.

· Present progress, performance improvements, and ROI/business cases for operational initiatives to senior leadership.

Experience & Qualifications

· Degree or Diploma in Industrial Engineering, Operations Management, Automotive Engineering, or equivalent practical experience.

· Lean Green Belt or Black Belt certification (or equivalent practical Kaizen / Six Sigma leadership).

· Minimum 3–5 years leading continuous improvement or process engineering initiatives within an automotive workshop, fleet maintenance facility, transport depot, or heavy machinery/commercial vehicle environment.

· Experience with automotive dealer management systems (DMS), Gemba Docs, electronic job ticketing, and data visualization tools (e.g., Power BI, Excel dashboards).

· Practical understanding of commercial vehicle repair mechanics, maintenance schedules, and CVRT/RSA roadworthiness compliance standards.

· Hands-on, “Gemba-first” mindset: willing to spend the majority of the day on the workshop floor, interacting directly with technicians and dispatchers.

What They Offer

· A competitive salary package reflective of the experience and responsibilities of the role.

· A professional and supportive working environment.

· Performance-related annual bonus.

· Company pension scheme.

· Ongoing manufacturer-specific training and professional development allowances.