Lean Specialist - Manufacturing

Role Overview

Lean Specialist - Manufacturing at Weatherford UAE. The role provides hands-on leadership in deploying, implementing, and sustaining the Weatherford Lean Program across assigned Repair & Maintenance facilities.

Role Purpose

The Lean Specialist translates business priorities into measurable improvements across safety, quality, delivery, cost, productivity, throughput, lead time, and capacity. The role establishes and sustains practical Lean management systems, builds organizational capability through coaching and structured improvement activities, and influences operational leaders and shop-floor teams across multiple facilities without direct authority.

Key Responsibilities

Lean Program Deployment & Sustainment

• Lead the deployment and sustainment of Weatherford Lean elements across assigned Repair & Maintenance facilities, aligned with business priorities, facility objectives, and product line roadmaps.
• Establish and sustain Shop Daily Management (SDM) and Office Daily Management (ODM) routines, including SQDC performance boards, KPI governance, action tracking, escalation, and leadership review.
• Establish and sustain Hoshin Kanri, visual performance management, Leader Standard Work, A3/PDCA, and structured problem-solving frameworks.

Process Analysis & Improvement Identification

• Conduct Value Stream Mapping, process mapping, time studies, and Gemba observations to identify waste, constraints, and improvement opportunities.
• Perform product-process analysis and load-versus-capacity assessments.
• Support facility layout, material flow, space utilization, and consolidation assessments to reduce unnecessary movement and storage, optimize facility footprint, and improve resource utilization.

Continuous Improvement Execution

• Facilitate Kaizen events and structured problem-solving activities using A3, PDCA, DMAIC, 5 Why, and root-cause analysis, ensuring actions are implemented, verified, and sustained.
• Deliver measurable improvements in throughput, cycle time, lead time, schedule adherence, backlog, overtime, productivity, quality, cost, and capacity utilization.
• Apply standardized productivity and operational performance measurement methods, validate reported benefits and savings, and ensure improvements are traceable, auditable, and sustainable.

Operational Systems & Performance Management

• Develop Hoshin scorecards, operational dashboards, and management reports using Excel, Power BI, JDE, MyAdvisor, Oracle, and other available systems to support data-driven decision-making.
• Manage KPI governance and ensure leadership review routines.

Planning, Scheduling & Material Flow

• Improve planning, scheduling, material flow, and information flow using standard work, pull systems, Kanban, FIFO, Heijunka, and relevant APICS principles where applicable.

Workplace Organization & Visual Management

• Implement and sustain 5S, workplace organization, Quality at the Source, visual management, standard work, and Leader Standard Work through coaching, audits, and follow-up routines.

Digital & Automation Initiatives

• Support the implementation of intelligent shop-floor solutions, robotics, and automation initiatives where applicable.

Capability Building & Leadership

• Build Lean capability by coaching leaders and employees, developing local Lean champions, and supporting a sustainable culture of continuous improvement.
• Coach and influence technicians, supervisors, managers, and senior leaders across multiple facilities without direct authority.

Stakeholder Communication & Management

• Manage multiple cross-functional improvement priorities and clearly communicate progress, risks, actions, and measurable results to stakeholders and leadership.
• Collaborate with Operations, Repair & Maintenance, Quality, Supply Chain, Materials Planning & Scheduling, Asset & Inventory, Distribution, Logistics, Procurement, Finance, HR, Digital, and Engineering.
• Maintain a strong presence at the Gemba.

Qualifications & Experience

• Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, Operations, or another relevant technical discipline.
• Minimum 5 years of professional experience in Lean, Continuous Improvement, Operational Excellence, Manufacturing, Repair & Maintenance, Aftermarket, Oilfield Services, or another heavy-industrial environment.
• Demonstrated experience delivering quantified and sustainable improvements in productivity, throughput, lead time, cost, quality, schedule adherence, backlog, or capacity.
• Hands-on experience implementing daily management systems and coaching operational leaders and shop-floor teams.
• Lean Bronze/Silver, Lean Six Sigma Black Belt, or equivalent certification is preferred; demonstrated practical Lean implementation and measurable business results are essential.
• APICS CPIM/CSCP certification or formal planning and scheduling training is an advantage and does not replace hands-on Lean implementation experience.
• Experience working across multiple functions, facilities, or product lines is preferred.

Skills & Competencies

• Strong practical knowledge of Lean Manufacturing, Continuous Improvement, and Operational Excellence methodologies.
• Proficiency in Value Stream Mapping, 5S, Visual Management, Standard Work, Kaizen, Kanban/Pull Systems, Hoshin Kanri, A3, PDCA, DMAIC, 5 Why, and Root Cause Analysis.
• Strong analytical and problem-solving capabilities with the ability to translate operational data into actionable improvements.
• Advanced Microsoft Excel skills.
• Experience with Power BI or similar data visualization tools preferred.
• Working knowledge of ERP and operational systems, with experience in JDE, MyAdvisor, Oracle, or comparable systems considered an advantage.
• Strong facilitation, communication, project management, and change management skills.
• Strong understanding of operational performance measurement and KPI management.
• Knowledge of benefits realization.
• Knowledge of planning, scheduling, material flow, and capacity management.
• Understanding of Industry 4.0, intelligent shop-floor technologies, robotics, and automation is an advantage.
• Strong ability to work in a cross-functional, multicultural, and multi-site environment.