Lean Operations Manager

About Bike Club

Bike Club is committed to making sustainable, premium-quality cycling accessible to families through a subscription service that ensures children always have the right-sized bike. Bikes grow with the children and are refurbished and passed on, contributing to a circular economy. With over 80,000 bikes in use, substantial funding exceeding $50 million, and expanding operations across Europe, Bike Club is poised for significant growth.

Role Overview

We are seeking a Lean Operations Manager based in our Rainham, London warehouse to spearhead continuous improvement initiatives throughout our intake, refurbishment, and fulfillment areas. This is a practical, hands-on position with extensive floor engagement, ideal for candidates eager to solve operational challenges by combining observation with data-driven strategies.

Responsibilities

• Lead continuous improvement initiatives across all operational stages including intake, refurbishment, dispatch, and returns, managing priorities and reporting outcomes to leadership.
• Conduct comprehensive value stream mapping from bike intake through to return, identifying inefficiencies and bottlenecks impeding process flow.
• Facilitate kaizen workshops, A3 problem-solving sessions, and root-cause analysis alongside mechanics, warehouse staff, and team leaders.
• Develop, monitor, and enhance key operational metrics such as cycle time, refurbishment throughput, first-time-right rate, on-time dispatch, returns processing, and overall equipment effectiveness (OEE).
• Implement Lean tools including standard work protocols, 5S, visual management, and pull-based flow within warehouse and workshop environments.
• Engage frequently with the warehouse workforce to observe practices, provide coaching, and ensure sustainable adoption of improvements.
• Plan capacity and workspace layouts scaling through workstation design, balancing, tool placement, and bike flow optimization.
• Collaborate with last-mile and courier partners to minimize failed deliveries, reduce returns leakage, and shorten customer wait times.
• Establish data management and reporting systems using Excel, warehouse management systems (WMS), Salesforce, and business intelligence tools to support fact-based operational decisions.
• Mentor team leads and operators in Lean methodologies to cultivate continuous improvement capabilities across the organisation.

Requirements

• Strong Gemba orientation with preference for on-floor operational involvement over desk-based roles.
• Demonstrated structured and analytical problem-solving skills, leveraging data analysis tools such as Excel to address complex operational issues.
• Excellent communication and collaboration skills to engage effectively with diverse stakeholders including mechanics, operators, and senior management.
• Highly organized, pragmatic, and action-focused mindset suited to dynamic, fast-paced growth environments.
• Relevant academic background in industrial engineering, logistics, supply chain management, business engineering, or related disciplines.
• Practical exposure to operations via internships, student work placements, early career positions, academic projects or equivalent hands-on experience.
• Strong interest in Lean and continuous improvement principles; certifications like Lean Six Sigma (Yellow, Green, or Black Belt) or hands-on experience implementing Kaizen or value stream mapping are advantageous.
• Comfortable working with operational systems such as WMS, ERP, Salesforce, and ticketing platforms; familiarity with SQL or BI tools is beneficial but not mandatory.
• Fluent proficiency in English is essential; German language skills are highly desirable.
• Additional interest or experience in circular economy initiatives, refurbishment processes, subscription-based business models, or sustainable mobility is a plus.

Benefits

• Generous leave entitlement: 25 days of annual holiday plus public bank holidays.
• Private medical insurance coverage.
• Eligibility for a salary sacrifice pension scheme.
• Enhanced maternity and paternity parental leave provisions.
• £30 discount on Bike Club bike subscriptions.
• Opportunity to contribute to environmental and social causes as part of a certified B Corp organisation.

Additional Information

This position welcomes candidates at varying stages of their career, especially those ready to step up into a mature operations role. Applicants early in their careers who show ambition, structure, and a drive to learn are encouraged to apply regardless of whether every requirement is met.