CASE STUDY 
Senior Lean Manager 

Brief

Our client, a leading Tier 1 automotive component manufacturer in NRW, Germany, was seeking a Senior Lean Manager to take their plant optimization to the next level. The position came with future succession planning into the Operations Director role within the next few years. The plant is a smaller facility with a leaner team, which presented unique challenges. The ideal candidate needed to excel not only in Lean and Continuous Improvement (CI) practices but also in a high-pressure environment where leadership and team motivation are key.

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Our Process

Our search strategy focused on identifying candidates who had a deep understanding of Lean and CI methodologies combined with a leadership background in managing smaller, high-demand plants. We targeted professionals within the automotive sector who had experience in Tier 1 manufacturing environments, with a particular emphasis on succession potential.

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• We leveraged our extensive network within the automotive manufacturing space across Europe and carried out a detailed assessment to match technical skills with cultural fit.

• Conducted thorough interviews to assess candidates’ ability to motivate teams, retain talent, and implement Lean methodologies successfully.

• We collaborated closely with the client’s senior leadership team to understand the operational dynamics and key challenges of the plant, ensuring the right candidate would be able to thrive in a smaller yet high-demand environment.

Challenges

The primary challenge was the size of the plant. With a smaller workforce, the candidate needed to wear multiple hats, balancing operational leadership with hands-on involvement in daily production challenges. In addition, the plant had faced employee retention issues, meaning the candidate had to be someone capable of driving team engagement, improving workplace culture, and retaining talent in a demanding environment.

Another challenge was the succession planning component. The selected individual had to demonstrate both an immediate impact on Lean processes and the long-term potential to transition into the Operations Director role, necessitating a blend of technical expertise and leadership acumen.

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Result

We successfully placed a highly skilled Lean Manager who not only had an extensive background in Lean and CI methodologies but also had a proven track record of excelling in small, demanding plants. The candidate brought extensive experience in employee engagement and retention strategies, aligning well with the plant's specific needs. Moreover, the selected candidate's personal growth ambitions aligned perfectly with the company's succession plan, making her a natural fit for future leadership roles.

Within her first few months, she integrated Lean principles that helped optimize workflows, reduce bottlenecks, and improve employee morale. Her leadership and strategic vision ensured a smooth transition into her role, setting the stage for future success as a key leader in the plant’s senior leadership team.