Continuous Improvement Engineer

Continuous Improvement Engineer Department: Continuous Improvement / Operations Reports To: Continuous Improvement Manager Location: Double H Plastics, Warminster Employment Type: Full-Time Date Written: 9/24/2026 Position Summary: The Continuous Improvement Engineer is responsible for identifying, analyzing, and implementing opportunities that improve the safety, quality, delivery, productivity, cost, and overall performance of manufacturing operations. This position will serve as a hands-on change agent within the organization, working directly with Operations, Engineering, Maintenance, Quality, Finance, IT, and executive leadership to understand problems, develop data-driven solutions, standardize improved processes, and ensure improvements are sustained. The ideal candidate is adept in multiple various arenas: analytical, technically capable, highly communicative, detail-oriented, and self-accountable. They should be comfortable moving between the production floor, data analysis, technical documentation, training, and executive-level discussions. This is an opportunity for someone who is hungry to create meaningful organizational change and wants to have a measurable impact on how a manufacturing organization operates. Key Responsibilities: • Continuous Improvement & Process Engineering • Identify, evaluate, prioritize, and lead continuous improvement opportunities throughout manufacturing operations. • Conduct time studies, work measurement, process flow evaluations, and value-stream mapping to identify waste, bottlenecks, capacity constraints, and opportunities for improvement. • Analyze current-state processes and develop future-state processes that improve efficiency, quality, safety, and throughput. • Lead or support Kaizen, Lean, Six Sigma, and structured problem-solving activities. • Develop and implement process improvements using data, observation, engineering principles, and cross-functional input. • Establish measurable baselines and performance targets before implementing improvements. • Monitor results following implementation to verify that improvements are achieving the intended outcome. • Develop standard work and process controls to sustain improvements. • Identify opportunities to eliminate unnecessary steps, reduce variation, improve material flow, and simplify processes. • Support capital equipment evaluations, process design, equipment implementation, and manufacturing process changes. • Data Analysis & Business Intelligence • Develop and maintain Power BI dashboards, reports, KPIs, and visual management tools that provide actionable operational information. • Extract, clean, analyze, and interpret data from ERP and other manufacturing systems. • Use Microsoft Excel extensively for data analysis, modeling, reporting, process analysis, and decision support. • Develop automated or semi-automated reporting tools where appropriate. • Translate operational data into meaningful information that can be understood by operators, supervisors, managers, and executives. • Identify trends, abnormalities, performance gaps, and opportunities through quantitative analysis. • Establish data-driven performance measurements for CI projects and manufacturing processes. • ERP / Manufacturing Systems • Work extensively with ERP and manufacturing information systems to understand how operational data is generated, recorded, and utilized. • Analyze ERP data to identify process, production, inventory, quality, maintenance, and operational improvement opportunities. • Partner with IT and functional stakeholders to improve the accuracy, usability, and effectiveness of manufacturing system data. • Assist with development, implementation, and standardization of ERP processes and workflows. • Identify opportunities to automate manual processes and improve data visibility. • Technical Documentation • Create and maintain high-quality technical documentation, including: • Standard Operating Procedures (SOPs) • Work Instructions (WIs) • Process documentation • Process maps • Training materials • Technical reports • Project documentation • Process specifications • Visual management materials • Translate complex technical processes into documentation that can be clearly understood and followed by employees at all levels of the organization. • Establish documentation standards that promote consistency, clarity, accuracy, and traceability. • Ensure process documentation reflects the actual process and is updated following approved changes. • Training & Change Management • Develop and conduct training associated with new or improved processes, systems, equipment, and standard work. • Facilitate training for production employees, supervisors, managers, and other stakeholders. • Communicate the why, what, and how behind process changes to build understanding and adoption. • Work directly with employees at all levels to understand operational challenges and develop practical solutions. • Help establish a culture where employees actively identify and participate in improvement opportunities. • Project Leadership & Stakeholder Management • Lead cross-functional improvement projects from problem identification through implementation and sustainment. • Develop project objectives, scope, timelines, deliverables, measurements, and action plans. • Coordinate activities among Operations, Engineering, Maintenance, Quality, IT, Finance, and other stakeholders. • Present project findings, recommendations, progress, and results to management and executive leadership. • Facilitate meetings with stakeholders at all organizational levels in a professional and productive manner. • Effectively challenge existing processes and assumptions when supported by data and engineering analysis. • Maintain accountability for assigned projects, action items, deadlines, and deliverables. Required Qualifications • Bachelor's degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, or another relevant STEM discipline. • 5 years of professional experience in a manufacturing environment. • Demonstrated experience with continuous improvement, process engineering, manufacturing engineering, operations engineering, or a related discipline. • Strong proficiency in Microsoft Excel. • Strong proficiency in Microsoft Power BI, including development of dashboards and data visualizations. • Experience working with ERP or manufacturing management systems. • Demonstrated ability to perform: • Time studies • Process flow analysis • Value-stream mapping • Process observation and evaluation • Root-cause analysis • Data analysis • Exceptional written and verbal communication skills. • Exceptional technical writing and documentation skills. • Ability to communicate effectively with hourly employees, supervisors, managers, engineers, executives, and external stakeholders. • Strong attention to detail and ability to maintain accuracy while managing multiple projects. • Demonstrated ability to work independently and maintain personal accountability for assignments and commitments. • Ability to conduct professional training sessions and technical presentations. • Ability to work effectively in both an office/data-analysis environment and on the manufacturing floor. Preferred Qualifications • The following qualifications are highly desirable: • Lean Manufacturing or Six Sigma certification. • Experience with process design or manufacturing process development. • Experience with Visual Basic / VBA. • Programming or scripting experience. • Experience developing Excel-based automation tools. • Experience integrating or manipulating data from ERP, MES, CMMS, or other manufacturing systems. • Experience with SQL, databases, APIs, or other data technologies. • Experience with Power BI data modeling, Power Query, and/or DAX. • Experience leading Kaizen events or structured improvement projects. • Experience with capital equipment selection, installation, commissioning, or process validation. • Experience developing Standard Work, SOPs, and Work Instructions. • Experience with Lean tools such as: • 5S / 6S • Value-Stream Mapping • Standard Work • Visual Management • Kaizen • Root-Cause Analysis • 5-Why • Fishbone/Ishikawa • SMED • OEE • Kanban • Process Flow Analysis Core Competencies • Analytical Thinking • Ability to break complex operational problems into measurable components, analyze data, identify root causes, and develop practical solutions. • Technical Communication • Ability to communicate technical information clearly, concisely, and professionally to audiences ranging from production employees to executive leadership. • Technical Writing • Ability to create documentation that is accurate, concise, organized, visually understandable, and usable by the intended audience. • Ownership & Accountability • Takes responsibility for projects and deliverables without requiring constant direction or follow-up. • Attention to Detail • Recognizes that small details in processes, data, documentation, and implementation can have significant operational consequences. • Change Leadership • Comfortable challenging the status quo, building stakeholder support, and moving an organization from the current state toward an improved future state. • Collaboration • Builds effective relationships across departments and organizational levels while maintaining focus on the objective. Considers all complaints and grievances as potential opportunities. • Manufacturing Mindset • Understands that solutions must work in the real manufacturing environment, not simply look good on paper or in a spreadsheet. Looks for the simplest solution before over-engineering a process. • Professionalism • Represents the Continuous Improvement function professionally when interacting with employees, management, executives, vendors, and external partners. What Success Looks Like • Within this role, success is demonstrated by the ability to: • Turn operational problems into clearly defined improvement opportunities. • Use data to establish fact-based baselines and measurable targets. • Identify waste, bottlenecks, process variation, and capacity constraints. • Develop practical solutions that can actually be implemented on the manufacturing floor. • Convert improved processes into sustainable standard work. • Build dashboards and analytical tools that allow the organization to see and understand its performance. • Reduce dependence on manual reporting and spreadsheet-based administration through automation. • Improve processes without creating unnecessary bureaucracy. • Train employees and leaders so improvements become part of the normal operating process. • Demonstrate measurable improvements in Safety, Quality, Delivery, Cost, Productivity, and Capacity. • Develop credibility with both manufacturing employees and executive leadership. • Take ownership of problems and consistently drive projects toward completion. The Ideal Candidate The ideal candidate is not simply someone who knows Lean terminology or can build a Power BI dashboard. We are looking for an engineer who wants to change how an organization operates. You should be comfortable walking onto a manufacturing floor, observing a process, talking with the people doing the work, collecting data, analyzing the process, building a solution, documenting the new standard, training the team, and then measuring whether the change actually worked. You should be equally comfortable taking those findings into a meeting with senior leadership and explaining the problem, the data, the proposed solution, the expected impact, and what is required to implement it. If you are analytical, technically curious, highly accountable, and motivated by solving difficult manufacturing problems-and you want your work to produce measurable organizational change-this position is designed for you.