Job Title: Senior Continuous Improvement Engineer
Location: Richmond, VA
What we are looking for:
We are looking for a Senior Continuous Improvement (CI) Engineer to have responsibility for driving the organization to target measurable and sustainable improvements across all operations and support functions. Expectations include co-owning strategy and tactical development and execution for site initiatives and coaching lean capabilities within the organization.
Responsible for designing, implementing, and revising the procedures and equipment required in the manufacturing process for process design and optimization. The successful candidate can assess, scope, plan, execute and deliver on industrial process improvements, in accordance and balance with all SQDIP metrics, and ensure process sustainability. Candidates will be expected to build & foster a business environment that embraces Kaizen / Continuous Improvement (CI) and structured problem solving as a key to the company's ongoing growth and success. The position is part of operations and will directly report to the factory CI Leader.
What you'll be responsible for in this role:
- Deploy SQDIP (Safety, Quality, Delivery, Inventory, Productivity) visual management boards and standard management routines across all organizational levels, aligning with the 0DOVER Operational Excellence framework.
- Champion the 0Dover OPEX Model, embedding Lean principles into daily operations. Coach and build capabilities across all levels on the 0DOVER model and standards.
- Conduct regular OPEX audits to ensure compliance with 0Dover model. Provide assistance in developing certification plan depending on required level and connect OpCos with corporate trainers.
- Lead and facilitate high impact Kaizen and rapid improvement events, value stream mapping, and structured problem solving with cross-functional teams. Ensure both manufacturing and logistics processes are optimally integrated: workstation design, part presentation, routings, tools, standard work, work instructions, visual management, Single minute exchange die (SMED), Plan for Each Part (PEFP), etc.
- Analyze production processes, schedules, methods, etc., and provide management with reports to enable the better understanding of future requirements needed for improving and optimizing the manufacturing process.
- Experience in developing SW (including production plans, takt planning, PFMEAs and Control Plans), workstation design, BOM routings & labor costs development, project management & vendor integration for new line equipment/process design implementation, and technology/systems integration.
- Review and calculate labor, material, and other production costs along with reviewing schedules and future production requirements to assist management in decision making. Analyze and plan workflow, equipment placement and space requirements to improve manufacturing efficiency and part flow. Focus on one-piece-flow and JIT principles.
- Apply improvement tools and develop the scope for assembly line design and implementations, fixtures, poka-yokes, tool making and supplier management under the scope of manufacturing process design across many facilities.
- Build and maintain KPI dashboards and reports (Power BI or similar); use data to prioritize projects and demonstrate ROI.
- Experience working with OT teams (MEs, tooling engineers, controls engineers, etc.).
What are the basic qualifications?
- Four (4) year degrees are required; a degree in Industrial Engineering, Manufacturing Engineering discipline is required
- 3-7 years of Continuous Improvement experience
- 2+ years Project Management experience
What are the preferred qualifications?
- Working knowledge of Lean / Six Sigma principles
- Proficiency in CAD software (e.g. SolidWorks, AutoCAD). AutoCAD skills required
- Proven hands-on understanding and experience in use and coaching of TPS/Lean Fundamentals (5S, SW, PSP, Kaizen, DM, VSM, TPI, Poka-Yoke, etc...)
- Cross functional experience in Operations / Material Flow / Supply Chain Mgmt. / Customer Support / Accounting / Product Development
- Excellent communication and interpersonal skills with the ability to collaborate effectively with cross-functional teams
- Ability to work independently and manage multiple projects simultaneously in a fast-paced environment
- Knowledge of ergonomic principles and safety standards in manufacturing
- Experience with Enterprise Resource Planning (ERP) systems (e.g., SAP, Oracle)
What's in it for you?
- Medical, Dental, and Vision
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