What This Role Is All AboutThe Senior Continuous Improvement Specialist leads strategic improvement and process-engineering initiatives across our manufacturing operations.
Working closely with Production leadership and cross-functional teams, this position uses Lean Manufacturing, Value Stream Mapping, Overall Equipment Effectiveness and advanced analytical tools to improve safety, quality, productivity, cost and material flow.
This is a hands-on role that combines shop-floor observation, data analysis, fixture and layout design, project leadership and employee engagement. The successful candidate will also help build continuous-improvement capability across the organization by mentoring junior engineers and analysts and supporting initiatives across multiple facilities.
What You'll Do- Conduct time studies, workflow analysis and value stream mapping to identify opportunities to improve productivity, safety, quality and cost.
- Lead OEE studies for production lines and critical equipment, including establishing measurement standards, baselines, targets and improvement roadmaps.
- Analyze availability, performance and quality losses using downtime, Pareto, TEEP and Six Big Losses data.
- Lead root-cause investigations and implement practical corrective and preventive actions.
- Plan and facilitate Kaizen events, define objectives, estimate ROI, coordinate resources and track measurable results.
- Lead Lean and continuous-improvement initiatives using 5S, Six Sigma, 8D, standard work, visual management and Kamishibai audits.
- Design production fixtures, workstations and layouts using SolidWorks, AutoCAD or similar 3D CAD tools.
- Use FlexSim or comparable simulation tools to evaluate production capacity, workflows and proposed process changes.
- Support line balancing, process design and validation, PFMEA, control plans and new-product introductions.
- Prepare labour ROI, work-content and capital-justification analyses for senior leadership.
- Create and maintain SOPs, work instructions and technical documents.
- Deliver hands-on training and demonstrations to production employees and cross-functional teams.
- Establish and lead a Continuous Improvement Steering Committee.
- Lead improvement and process-engineering projects from business case through implementation and sustainment.
- Mentor junior engineers and analysts and help build a sustainable culture of operational excellence.
- Support improvement initiatives across multiple Durabuilt facilities.
What You Bring- Bachelor's degree in Industrial, Mechanical, Manufacturing or a related engineering discipline, or a technical diploma combined with equivalent senior-level experience.
- At least six years of experience in a manufacturing environment, including a minimum of two years leading continuous-improvement or process-engineering projects.
- Lean Six Sigma Green Belt certification is required; Black Belt certification is an asset.
- P.Eng., E.I.T. or C.Tech designation is an asset.
- Strong knowledge of Lean Manufacturing, 5S, Kaizen, Six Sigma, 8D, value stream mapping and root-cause analysis.
- Advanced knowledge of OEE, including measurement rules, loss categorization, Six Big Losses analysis and improvement validation.
- Experience with automated OEE data collection through PLC, MES or IIoT systems is an asset.
- Experience conducting time studies, capacity analysis, line balancing and process-efficiency evaluations.
- Proficiency with SolidWorks, AutoCAD or similar CAD tools for fixture and layout design.
- Experience with FlexSim or equivalent manufacturing simulation software.
- Knowledge of process design and validation, PFMEA, control plans and standard work.
- Advanced statistical-analysis knowledge, including SPC, Cp/Cpk, MSA, Gage R&R, hypothesis testing and DOE.
- Experience using Minitab or equivalent statistical software.
- Strong data-analysis skills using Excel, Power BI or SQL; Python or other scripting experience is an asset.
- Experience preparing SOPs, work instructions, technical reports and training materials.
- Demonstrated ability to build business cases, calculate ROI and support capital-investment decisions.
- Strong project leadership, mentoring and cross-functional collaboration skills.
- Excellent communication, problem-solving and organizational abilities.
- Experience in high-volume manufacturing is required; window and door manufacturing experience is an asset.
Working Conditions and Requirements- Primarily works in an office and manufacturing-plant environment.
- Regular presence on the production floor is required.
- Must be comfortable working around machinery, production equipment, noise and changing operational demands.
- Ability to lift or carry between 10 and 75 pounds when required.
- Uses office and technical equipment, including computers, smartphones and 3D printers.
- Valid driver's license required.
- Ability to travel between local facility locations as needed.
- Occasional weekend availability may be required.
- Must be able to manage multiple projects, tight timelines and a high level of detail.
Why Join Durabuilt?- Lead high-impact improvement projects across a growing manufacturing organization.
- Influence operational strategy and help shape our continuous-improvement culture.
- Work directly with production teams, technical professionals and senior leadership.
- Mentor developing professionals and support improvements across multiple facilities.
- Join a Canadian company recognized for innovation, quality and long-term growth.
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