Offsite Construction & Modern Methods of Construction (MMC)
Location: Munster
Contract Type: Full-Time Consultancy Assignment (12-Month Initial Engagement)
Reporting To: Managing Director / Senior Leadership Team
About the Business
Our client is a leading offsite construction and advanced manufacturing business specialising in the design, manufacture and delivery of engineered building systems for the construction sector.
Operating within the rapidly growing Modern Methods of Construction (MMC) sector, the company is committed to driving innovation, operational excellence and continuous improvement across its design, manufacturing and project delivery functions.
As part of its ongoing growth and transformation journey, the business is seeking to appoint an experienced Continuous Improvement & Operational Excellence Consultant to support the development of world-class manufacturing capabilities while strengthening quality systems, workforce capability and product industrialisation processes.
The Opportunity
This is a unique opportunity for an experienced Operational Excellence professional with a strong understanding of offsite construction, industrialised building systems and Design for Manufacture and Assembly (DFMA).
The successful candidate will work across manufacturing, engineering, quality and design functions to improve operational performance, support workforce development and help industrialise products and processes to support future growth.
The role requires an individual who is equally comfortable working on the shop floor, facilitating improvement workshops, analysing operational data and engaging with senior leadership teams.
This is not a traditional Lean Manufacturing role. We are seeking an individual who understands the unique challenges of industrialised construction, where manufacturing excellence, product design, logistics and site installation must operate as an integrated system.
Key Responsibilities
Continuous Improvement & Operational Excellence
- Develop and implement a structured Continuous Improvement roadmap aligned to business objectives.
- Lead Lean Manufacturing and Operational Excellence initiatives across production, assembly, logistics and support functions.
- Conduct value stream mapping exercises to identify waste, bottlenecks and opportunities for improvement.
- Implement and sustain Lean tools including 5S, Visual Management, Standard Work, Kaizen, Root Cause Analysis and Daily Management Systems.
- Improve key business metrics including productivity, labour efficiency, quality performance, OTIF delivery, lead times and operational cost performance.
- Establish governance structures to monitor improvement initiatives and ensure benefits realisation.
- Develop internal Continuous Improvement capability through coaching, mentoring and knowledge transfer.
Training & Workforce Capability
- Conduct workforce capability assessments and skills gap analyses across production, engineering and support functions.
- Develop and implement structured training and competency development programmes.
- Establish competency matrices and progression pathways for key operational roles.
- Develop and standardise SOPs, work instructions and visual management systems.
- Support onboarding, cross-training and multi-skilling initiatives.
- Promote a culture of continuous learning and employee engagement.
- Work closely with supervisors and managers to strengthen problem-solving capability and operational ownership.
Product Development & Industrialisation
- Support the industrialisation of new products, systems and manufacturing processes.
- Collaborate with Design and Engineering teams to improve product manufacturability and assembly efficiency.
- Apply Design for Manufacture and Assembly (DFMA) principles to support standardisation and repeatability.
- Lead PFMEA activities, Control Plans, pilot builds and process validation activities.
- Improve design-to-manufacture workflows and reduce waste associated with engineering changes and product variation.
- Develop standardised production documentation, routings, bills of materials and traceability systems.
- Support New Product Introduction (NPI) activities and manufacturing readiness reviews.
Offsite Construction & MMC Systems
- Support the continuous improvement and industrialisation of offsite construction systems including panelised, modular, volumetric, timber frame, light gauge steel, precast concrete and hybrid solutions.
- Develop a strong understanding of manufacturing-to-site interfaces and opportunities to improve installation efficiency.
- Support initiatives that improve logistics planning, sequencing, traceability and quality assurance throughout the product lifecycle.
- Work with design, manufacturing and project teams to improve integration across the entire project delivery process.
- Identify opportunities to reduce product complexity and improve standardisation.
- Contribute to the development of digital design-to-manufacture workflows.
- Support the implementation of DFMA principles across product and process development activities.
Quality, Compliance & Management Systems
- Maintain and continuously improve the Quality Management System in accordance with ISO 9001 and relevant industry standards.
- Support compliance with applicable construction product standards and certification requirements.
- Conduct internal audits, process reviews and compliance assessments.
- Lead non-conformance investigations and corrective action processes.
- Improve quality assurance processes and right-first-time performance.
- Develop KPI reporting structures to improve visibility of quality performance.
- Support external audits and certification activities.
Business Improvement & Performance Management
- Support senior leadership in the development and execution of Operational Excellence strategies.
- Develop KPI dashboards and performance reporting frameworks.
- Facilitate improvement workshops and cross-functional problem-solving activities.
- Provide regular progress reports to the leadership team.
- Identify opportunities to improve profitability, customer satisfaction and organisational effectiveness.
About You
Essential Experience
- Minimum 5 years' experience within offsite construction, modular construction, timber frame manufacturing, precast concrete, steel fabrication, building products manufacturing or a related industrialised construction environment.
- Strong understanding of Modern Methods of Construction (MMC) and Design for Manufacture and Assembly (DFMA).
- Experience working across design, engineering, manufacturing and project delivery functions.
- Proven track record delivering Continuous Improvement and Operational Excellence programmes.
- Experience supporting product industrialisation and manufacturing process development.
- Strong understanding of manufacturing quality systems and structured problem-solving methodologies.
- Experience developing workforce capability, training programmes and competency frameworks.
- Strong communication, facilitation and stakeholder engagement skills.
- Ability to influence and engage individuals at all levels of the organisation.
Desirable
- Experience with panelised, modular, volumetric, timber frame, light gauge steel, precast concrete or hybrid construction systems.
- Familiarity with BIM-enabled manufacturing and design-to-manufacture workflows.
- Experience using platforms such as Tekla, Revit, Vertex, StrucSoft, MWF or similar systems.
- Knowledge of ISO 9001, EN1090, CE Marking, BOPAS, NHBC Accepts or similar industry standards.
- Lean Six Sigma Green Belt or Black Belt certification.
- Experience implementing ERP, MES or Power BI reporting systems.
Success in the Role
Within the first 12 months, the successful candidate will be expected to:
- Establish a structured Continuous Improvement roadmap.
- Improve productivity and labour efficiency across manufacturing operations.
- Reduce waste, rework and non-value-added activities.
- Strengthen workforce capability through structured training and development.
- Improve quality performance and compliance metrics.
- Enhance design-to-manufacture and manufacturing-to-site workflows.
- Support the successful industrialisation of new products and systems.
- Contribute to the development of a sustainable culture of Continuous Improvement and Operational Excellence.
Why Join This Opportunity?
- Opportunity to play a key role in the transformation of a leading MMC business.
- High level of visibility and influence across the organisation.
- Exposure to manufacturing, engineering, design and project delivery functions.
- Opportunity to shape the future development of industrialised construction systems.
- Competitive remuneration package.
- Potential for long-term engagement and career progression.
Work Location: In person
