ABOUT THE ROLE The Continuous Improvement (CI) Engineer leads and facilitates continuous improvement initiatives across the precast concrete manufacturing operation. This position drives operational excellence by using Lean Manufacturing, problem-solving methods, and data-driven decisions to improve safety, quality, productivity, equipment reliability, and cost performance. The CI Engineer works closely with production, maintenance, quality, engineering, and leadership teams to identify improvement opportunities, develop sustainable solutions, and ensure long-term process stability.
A key responsibility of this role is participating in and coaching Tiered performance review meetings, analyzing operational metrics and Pareto chart data, and converting identified trends into structured continuous improvement projects that deliver measurable business results.
This position reports to the SVP of Continuous Improvement and has no direct reports. The CI Engineer leads through influence, coaching, and cross-functional collaboration. Travel: 10-15% between other locations, as needed.
Salary range ($105,000-$130,000). Based on location and experience.
SAFETY IS OUR HIGHEST PRIORITY. Safety is our highest priority. We believe a safe workplace is built on mutual respect, care, and accountability. Every team member is empowered and expected to follow safety practices, look out for one another, and speak up about potential risks. Together, we create an environment where everyone goes home safely each day.
WHAT WE OFFER Wells provides a competitive benefits package designed to support employees• health, financial well-being, and work-life balance. Benefits include medical, dental, and vision insurance, company-paid disability and life insurance, wellness incentives, paid holidays, PTO, flexible spending accounts, HSA options, a 401(k) with profit sharing, access to Nice Healthcare, employee assistance resources, pet insurance, and additional voluntary coverage such as critical illness, accident, and hospital indemnity plans.
- Health and family care leave is available to both union and non-union employees.
- Union employee benefits are provided through separate collective bargaining agreements
WHAT YOU'LL DO Tiered Meetings and Data Analysis - Participate in and provide coaching for daily, weekly, and monthly Tiered (1• 4) performance review meetings to review key performance indicators (KPIs), identify operational trends, and prioritize improvement opportunities. SEPQDC refers to Safety, Environment, People, Quality, Delivery, and Cost.
- Tier 1: Plant-specific SEPQDC metrics with Plant Leadership - Weekly/Monthly
- Tier 2: 8-Step Problem-Solving Reviews with Department Leadership - Weekly
- Tier 3: Gemba walks focused on department SEPQDC metrics • Daily
- Tier 4: Departmental Hour-by-hour / task-specific review • Daily
- Analyze Pareto charts and other performance data from the Tiered meetings to identify recurring losses, production constraints, quality defects, downtime events, and safety concerns.
- Assist in developing plant performance metrics and reporting systems that support continuous improvement efforts.
Project Leadership and Problem Solving - Lead the plant's continuous improvement program and promote a culture of operational excellence throughout the organization.
- Develop, prioritize, and manage continuous improvement projects based on data-driven opportunities identified through Tiered reporting.
- Establish project objectives, timelines, success metrics, and accountability measures for improvement initiatives.
- Facilitate root cause analysis using structured 8-Step Problem-Solving methodologies along with 5-Why, Fishbone Diagram, and Process Mapping.
- Lead cross-functional improvement teams in implementing corrective and preventive actions to eliminate waste and improve process performance.
- Coordinate activities among departments to ensure successful project execution and sustainability.
- Monitor project progress and report results to plant leadership through visual management systems and performance dashboards.
- Track and verify realized improvements related to productivity, quality, safety, uptime, material utilization, and labor efficiency.
Lean Implementation and Process Improvement - Conduct process observations, workflow studies, and value stream mapping activities to identify inefficiencies and bottlenecks.
- Identify and reduce losses specific to precast production, such as mold/form changeovers, curing cycle time, batching and rebar fabrication flow, crane and yard logistics, and finishing or patching rework.
- Support implementation of Lean Manufacturing principles, including:
- 5S Workplace Organization
- Standard Work
- Visual Management
- Waste Elimination
- Continuous Flow
- Develop and maintain standard work procedures to support sustainable process improvements.
- Facilitate Kaizen events, improvement workshops, and employee engagement activities.
Coaching and Collaboration - Provide coaching, guidance, and training to supervisors and employees participating in CI initiatives, specifically on CI tools and methodologies.
- Collaborate with production supervisors, maintenance personnel, quality teams, and engineering staff to identify process improvement opportunities.
- Partner with maintenance and engineering teams to improve reliability and process capability.
Safety, Compliance, and Strategic Support - Ensure all improvement activities comply with company safety policies, quality standards, and regulatory requirements.
- Apply CI tools to support plant safety initiatives and build safety into standard work.
- Support annual strategic initiatives and operational improvement goals established by plant leadership.
WHO WE'RE LOOKING FOR The ideal candidate is a
motivated continuous improvement professional with experience in manufacturing operations and a passion for driving operational excellence through data-driven decision making. They are skilled in Lean Manufacturing principles, root cause analysis, and leading cross-functional teams to improve
safety, quality, productivity, and equipment
reliability. This individual thrives in a
hands-on environment, effectively
analyzes performance data to identify opportunities, and
works collaboratively to implement sustainable process improvements that deliver measurable results.
IDEAL CANDIDATE WILL HAVE - Bachelor's degree in Engineering, Manufacturing, Operations Management, Industrial Technology, or a related field preferred.
- Equivalent combinations of education, technical training, and relevant manufacturing or continuous improvement experience will be considered in lieu of a degree.
- Minimum of three to five years of manufacturing, operations, continuous improvement, or supervisory experience preferred.
- Strong understanding of Lean Manufacturing principles and continuous improvement methodologies.
- Ability to interpret operational data and identify meaningful trends and opportunities.
- Proficiency with Pareto analysis, root cause analysis, and corrective action processes.
- Strong analytical and problem-solving skills.
- Excellent communication and presentation abilities.
- Ability to influence and motivate employees at all levels of the organization.
- Strong project management and organizational skills, including the ability to manage multiple projects simultaneously and meet deadlines.
- Proficiency with Microsoft Office applications, particularly Excel. Experience with Power BI / AI is a plus.
- Knowledge of manufacturing performance metrics and KPI management systems.
- Experience in precast concrete or a similar heavy manufacturing environment is a plus.
MEASURES OF SUCCESS: Performance in this role is evaluated on measurable results, such as:
- Improvement in OEE and Labor Efficiency
- Number of CI projects completed and sustained each year
- Documented annual cost savings or cost avoidance
- Timely closure of corrective actions identified in Tiered meetings
- Reduction in scrap, rework, and quality non-conformity reports (NCRs)
WORKING CONDITIONS/PHYSICAL REQUIREMENTS - Ability to walk production areas regularly and spend extended periods on the manufacturing floor.
- Ability to walk production areas regularly and spend extended periods on the manufacturing floor.
- Ability to climb stairs, ladders, and access elevated work areas as needed.
- Ability to occasionally lift up to 25 pounds.
- Ability to work in an industrial manufacturing environment with exposure to dust, noise, vibration, and varying temperatures, including outdoor yard conditions.
- Ability to wear required personal protective equipment (PPE), such as hard hat, safety glasses, hearing protection, and safety footwear.
- May be exposed to moving equipment, machinery, and other standard industrial hazards.
- May be exposed to outdoor weather conditions, including heat, cold, wind, rain, as well as noise, dust, and vibration.
This profile summarizes key duties and expectations but does not list every possible job task. Employees must follow all job-related instructions and duties assigned by supervisors.
