SCOPE OF ROLEThe Continuous Improvement (CI) Manufacturing Engineer will proactively identify opportunities to eliminate waste, reduce variation, and improve productivity in manufacturing, while facilitating kaizen events with cross-functional teams to ensure seamless integration of CI principles into product and process design. This position is ideal for a hands-on problem solver who thrives in fast-paced environments and is passionate about building sustainable systems that support innovation and growth.
Additionally, this role is responsible for leading the introduction of new products into manufacturing, ensuring seamless integration from design to production. This role bridges engineering, operations, and quality to deliver products that meet performance, cost, and schedule targets.
ESSENTIAL DUTIESContinuous Improvement:- Lead and facilitate Kaizen events, problem solving, and other lean activities to drive measurable improvements.
- Develop and implement standard work, visual management systems, and 5S programs.
- Identify and implement improvements for new product lines to enhance quality, cost, and delivery through 3P Kaizen methodology.
Project Management:- Lead cross-functional teams through the NPD (New Product Development) process from design validation to product launch.
Manufacturing Readiness:- Develop and validate manufacturing processes, packaging and labeling, testing, work instructions, standard work and tooling for new products.
Design for Manufacturability (DFM):- Collaborate with design engineering to ensure products are optimized for efficient assembly and quality.
Process Validation:- Conduct PFMEA, capability studies, and pilot builds to ensure robust production processes.
Training & Documentation:- Support training of production staff and ensure documentation is complete and standardized.
Metrics & Reporting:- Track NPI KPIs such as first-pass yield, ramp-up time, and launch readiness.
- Subject Matter Expert (SME) and trainer of CI tools (Mixed Model Lean, Six Sigma, SIOP, Sourcing, GDP, and KPIs).
- Works to grow revenue & profit by delivering strong operational performance (SQDC).
- Lead efforts to identify opportunities for automation and implementing automation projects
- Utilize 80/20 methods, Lean Manufacturing, & Six Sigma tools drive focus on critical items that will yield the highest impact to the organization.
- Establish CI Roadmap that deploys actions to achieve strategic goals.
- Drives consistency and effective adoption of CI deployment in all areas.
- Implement problem solving principles to identify root cause and corrective actions
- Will help develop and maintain operational excellence and Quality KPI's and countermeasures
- Hands on participant of the Continuous Improvement/Kaizen processes by leading Rapid Improvement Events (RIE's).
- Support Goal Deployment Action Plans and improvement targets for the enterprise.
- Drive sustainable and consistent quality processes throughout Gast/JUN-AIR with sound root cause analysis and countermeasures.
- Build trust and credibility by leading by example.
- Create regular communications with the value stream and vertical businesses (clear direction, regular updates on events/decisions, and accountability for achieving & sustaining RIE results).
Measures of Performance - Sustainable performance improvements in Safety, Quality, OTD, Lead-time reduction, Inventory Turns, and PBIT
- Timely and successful completion of various business transformation projects
- Significant improvement in First pass yield, warranty claims, and customer quality complaints
- Identification and implementation of transformational manufacturing processes (automation implementation, Poke-Yoke processes, material movement technology)
EDUCATION AND EXPERIENCE REQUIREMENTS OR EQUIVALENCIES- Bachelor's degree in manufacturing, business, engineering discipline, or technical degree.
- 5+ years of production experience preferred.
- Strong continuous improvement background with knowledge of 5S, Kaizen, Lean and Value
- Experience in identification of large cost centers and systematically driving improvement to obtain organizational goals for a product manufacturing facility
- Value Stream Mapping
- Background with selection and implementation of automated equipment
- Hands on responsibility for manufacturing product quality
- Advanced understanding of ISO and Quality Management Systems
- History of results-based approach to developing and implementation of productivity funnel through the utilization of Kaizen
- Advanced knowledge of CI tools (Mixed Model Lean, Six Sigma, SIOP, Sourcing, GDP, and KPIs)
KEY COMPETENCIES- Drive for results / high sense of urgency
- Solid problem-solving methodology and demonstrated skill
- Integrity and trust
- Interpersonal savvy
- Strong leadership and influential skills
- Strong communication/presentation skills
- Strong data analyzation skills and strategy development
- Mentoring, development, and accountability
The intent of this job description is to provide a representative summary of the essential duties and responsibilities performed by incumbents of this job. Incumbents may be requested to perform job-related tasks other than those specifically presented.
