Continuous Improvement Engineer

Continuous Improvement Engineer

Position Objective

The Continuous Improvement Engineer serves as a process subject matter expert (SME) for manufacturing operations and plays a key role in leading and supporting the shift toward a sustainable Lean culture. This position focuses on stabilizing processes, bringing them under control, and sustaining improvements over time through lean manufacturing, structured problem solving, data-driven analysis, collaboration, and the effective use of automation supported by ROI justification.

Key Responsibilities

Process Ownership & Continuous Improvement

• Serve as a process subject matter expert for assigned manufacturing processes, understanding process flow, capability, constraints, and risks.
• Lead efforts to bring processes into statistical control and sustain gains using standard work, control plans, SPC, and visual management.
• Recommend and implement improvements to production processes, methods, and controls.
• Apply analytical and creative thinking to solve manufacturing problems and improve performance.

Lean Culture & Change Leadership

• Lead, support, and facilitate the ongoing shift toward a Lean culture across the organization.
• Act as a coach and change agent by helping teams understand why Lean practices are used, not just how.
• Encourage employee engagement and ownership of continuous improvement at all levels.
• Partner with leaders and teams to reinforce Lean behaviors, standard work, and continuous improvement routines.
• Help embed Lean thinking into daily management systems and decision-making.

Structured Problem Solving

• Utilize at least one structured problem-solving methodology , such as:
  • DMAIC
  • PDCA
  • Shainin Red X
• Define problems clearly, identify and validate root causes, implement effective solutions, and establish controls to sustain results.
• Support team-based problem-solving activities and knowledge sharing.

Lean Manufacturing & Kaizen

• Apply lean manufacturing principles and tools, including:
  • 5S and visual workplace
  • Kaizen activities and events
  • Standard work
  • Kanban and pull systems
  • Takt time analysis, line balancing, and line pacing
  • Waste identification and elimination
• Facilitate and participate in cross-functional Kaizen events , recognizing the value of collaboration across Operations, Engineering, Quality, Maintenance, and Supply Chain.
• Support continuous improvement through hands-on involvement in shop-floor activities.

Manufacturing Systems, Layout & Methods

• Plan, design, implement, and improve manufacturing systems that support performance, reliability, maintainability, schedule adherence, and cost control.
• Establish methods, equipment, and layouts for direct and indirect labor using time studies and predetermined time systems (e.g., MTM).
• Analyze layouts, material flow, and work methods; recommend changes to improve safety, efficiency, and throughput.
• Prepare and maintain process documentation and manufacturing layouts.

Equipment, Automation & ROI Justification

• Identify opportunities for tooling, equipment upgrades, and industrial automation to improve process capability, ergonomics, quality, and labor efficiency.
• Design, develop, test, source, and implement machinery, tooling, fixtures, and equipment.
• Support equipment procurement and implementation, including installation and process validation.
• Develop ROI and cost-justification analyses for capital and improvement projects, including savings estimates and payback considerations.

Data, SPC & Performance Management

• Implement and maintain Statistical Process Control (SPC) for variable and attribute data.
• Use data analysis to support cost reduction, quality improvement, and efficiency efforts.
• Support teams in understanding and using KPIs to monitor and improve process performance.

New Product & Process Launch

• Coordinate maufacturing launches for new or revised products, including goal setting, training, and performance evaluation.
• Participate in concurrent engineering and design reviews to support manufacturability and robust process design.

Communication, Training & Collaboration

• Participate in production and department meetings.
• Communicate changes and improvements through visual, written, and verbal instructions.
• Train personnel on new processes, systems, and Lean tools as needed.
• Standardize procedures to support consistency and sustained results.