Manufacturing Critical Thinking Consultant (Lean / TPS) – Discovery, Scenario planning & Delivery
Title Manufacturing Critical Thinking / Problem-Solving Consultant (Lean / TPS) – Custom Scenario-Based Training + Implementation Coaching Overview We are seeking an experienced consultant to support a customized critical thinking and problem-solving program for a manufacturing client (automotive manufacturing; Lean/Toyota mindset). The client already uses A3 / 5 Whys / Fishbone and similar tools. The gap is critical thinking behaviors and mindset before tool use, especially reducing premature escalation and improving structured diagnosis on the shop floor. This engagement is with a cross-functional team (9–12 participants), with the expectation that the consultant can support the program end-to-end: discovery, scenario design, experiential workshop delivery, and follow-up implementation coaching. Scope of Work (End-to-End) Phase 1 – Discovery & Process Understanding •Conduct stakeholder interviews (L&D + plant leadership + prototype area leaders) • Review example problem-solving artifacts (A3s, escalation patterns, standard work expectations) • Identify recurring problem themes and decision breakdown points Phase 2 – Scenario & Exercise Design • Build 6–10 realistic shop-floor scenarios tailored to client processes • Create workshop exercises and debrief guides • Develop lightweight job aids (problem framing prompts, diagnostic checklist) Phase 3 – Workshop Delivery (Experiential) • Deliver modular sessions (4–5 hours each), heavy on practice/role play/simulations • Facilitate cross-functional problem-solving using client scenarios Phase 4 – Implementation Coaching & Follow-Up • Coach the team through a real improvement project post-training • Run a follow-up session (~1 month later) and produce a concise readout Deliverables • Discovery summary + training architecture • Scenario pack + facilitator guide • Participant job aids • Live workshop delivery • Follow-up session + implementation readout Required Background • 7+ years in manufacturing operations, CI/Lean, or operational excellence (preferred) • Demonstrated experience facilitating problem-solving workshops (A3 / TPS mindset strongly preferred) • Strong capability in critical thinking / decision quality / root cause reasoning • Experience translating real operational issues into scenario-based training • Comfortable working with cross-functional plant teams (maintenance, quality, engineering, logistics) • Willingness to travel for the full or part-duration of engagement Nice-to-Have • Experience with automotive / heavy manufacturing environments • Experience coaching frontline leadership behaviors Engagement Details • Location: US East Coast City (remote, on-site or hybrid based on client preference) • Cohort size: 9–12 participants • Timing: Proposal phase now; delivery First Half of 2026 (prototype first) • Estimated consultant effort: ~80–100 hours depending on scope (we’ll align upfront) Screening Questions (Must Answer) 1. Describe a manufacturing-focused critical thinking/problem-solving workshop you delivered. What changed operationally afterward? 2. Provide an example of how you built scenarios from real plant problems (brief outline is fine). 3. What is your approach to improving “diagnosis before escalation” behaviors? 4. Are you able to support this engagement end-to-end (discovery → delivery → coaching)? 5. Are you available for on-site work US East Coast? If yes, what is your base location? Apply tot his job