Process Improvement Engineer

Process Engineer

The Process Engineer is responsible for driving continuous process improvement initiatives to achieve customer satisfaction and operational excellence in a manufacturing environment. This role focuses on analyzing, optimizing, and improving business processes using proven methodologies such as Lean and Six Sigma. This position reports to the Director of Continuous Improvement.

Essential Functions

Other duties may be assigned

• Implement Lean principles and practices for process improvement.

• Lead process improvement projects to reduce variation and enhance efficiency.

• Apply statistical thinking and problem-solving techniques to identify root causes and implement solutions.

• Foster strong relationships with colleagues to ensure service quality.

• Promote employee involvement and collaboration in process improvement initiatives.

• Utilize tools and frameworks such as Six Sigma and Lean to optimize workflows.

• Ensuring that all assembly processes operate within lean manufacturing principles (Value Stream Mapping, Five S, Kanban, and poka-yoke).

• Identification of manufacturing process improvements to existing process at CM and tiered supplier base to include a cost benefit analysis to allow senior evaluation and approval.

• Lead or support the startup of new/existing projects/production jobs, optimizing cost, efficiency and quality.

• Conduct workflow analysis and make recommendations for improvement in material handling and shop layout

• Lead or support the process control and maintain appropriate documentation.

• Understand the complexity of business and operational processes and workflows

• Work with various department managers to develop and present best-in-class continuous improvement strategies/processes

• Proactively identify where processes can be adapted and optimized to ensure cost effectiveness.

• Develop process analysis and re-engineering to improve efficiency, lower costs and improve product quality.

• Develop an in-depth knowledge of our supply base; strengths and weaknesses of internal procedures and business processes; strengths and weaknesses of equipment; and the strengths and weaknesses of key contributors to identify areas of improvement

• Support process team in identifying, analyzing, implementing and verifying process improvement and process re-engineering opportunities.

• Provide technical and analytical support for process improvement initiatives.

• Develop ROI's for capital expenditures and process changes.

• Facilitate the design and implementation of new/improved process models and manufacturing processes

• Train and guide resources in process improvement techniques.

• Work with management to help process team achieve desired results.

• Assist in development of new process capabilities.

• Research new equipment capable of improving quality and lowering cost.

• Perform project management, analytics, and measure to ensure milestones are met and deliverables achieved after projects are implemented.

• Coordinate with various teams to analyze project results and performance. If performance is not equal to expected result Identify where additional changes can be made to achieve desired results.

• Identify and manage resources to deliver effective solutions.

• Partner with the operations team to develop effective training tools and resources to ensure shop cleanliness.

• Knowledge of CPI methodologies including TOC, Lean Thinking, and Six Sigma.

• Strong analytical skills with experience in variation analysis and statistical methods.

• Excellent communication and collaboration skills.

• Ability to lead and influence cross-functional teams.

• Familiarity with CPI/TLS approach for establishing a culture of continuous improvement.

Other Essential Duties

• Maintains regular and consistent job attendance, comes to work on time

• Exudes IE Core Values - leads by example

• Follow and comply with IE safety program and cardinal safety rules.

Key Competencies:

To perform the job successfully, an individual should demonstrate the following competencies:

Analytical - Designs workflows and procedures

Design - Demonstrates attention to detail

Problem Solving - Identifies and resolves problems in a timely manner

Technical Skills - Strives to continuously build knowledge and skills

Customer Service - Responds promptly to customer needs; Meets commitments

Interpersonal - Remains open to others' ideas and tries new things

Oral Communication - Speaks clearly and persuasively in positive or negative situations.

Teamwork - Contributes to building a positive team spirit; Supports everyone's efforts to succeed

Written Communication - Writes clearly and informatively; Edits work for spelling and grammar; Presents numerical data effectively.

Change Management - Develops workable implementation plans to improve manufacturing processes

Leadership - Inspires respect and trust; Gives appropriate recognition to others.

Quality Management - Looks for ways to improve and promote quality; Demonstrates accuracy and thoroughness.

Business Acumen - Understands business implications of decisions; Displays orientation to profitability; Demonstrates knowledge of market and competition.

Cost Consciousness - Develops and implements cost saving measures and plans to reduce waste; Contributes to profits and revenue.

Diversity - Promotes a harassment-free environment

Ethics - Keeps commitments; Upholds organizational values

Organizational Support - Follows policies and procedures.

Strategic Thinking - Develops strategies to achieve organizational goals

Adaptability - Manages competing demands.

Attendance/Punctuality - Is consistently at work and on time.

Dependability - Takes responsibility for own actions.

Innovation - Meets challenges with resourcefulness.

Judgment - Exhibits sound and accurate judgment; Supports and explains reasoning for decisions.

Motivation – Demonstrates persistence.

Planning/Organizing - Prioritizes and plans work activities.

Professionalism - Approaches others in a tactful manner

Quality - Looks for ways to improve and promote quality.

Quantity - Meets productivity standards.

Safety and Security - Observes safety and security procedures.

Preferred Qualifications:

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed are representative of the knowledge, skill, and/or ability required. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Education/Experience: Bachelor's degree in Process Engineering or similar from a four-year college or university and 3 – 5 years of experience in manufacturing strongly preferred. An equivalent combination of education and experience could be considered.

Language Ability: Ability to read, analyze, and interpret blueprints and drawings, general business reports, government regulations such as OSHA, MSHA, UL, ISO quality requirements, etc. Ability to write SOPs, continuous improvement programs, progress reports, business correspondence, and procedure manuals. Ability to effectively present information and respond to questions from groups of managers, clients, customers, and the general public.

Math Ability: Must be able to calculate figures using statistics, ratios, basic algebra as well as multiplication, division, addition and subtraction.

Reasoning Ability: Ability to solve complex problems and deal with a variety of variables in situations where only limited standardization exists. Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form.

Computer Skills: To perform this job successfully, an individual should have knowledge of Must be proficient in Microsoft Office Products, processing software; Must be proficient with Excel Spread Sheets spreadsheet software and must be proficient with EPICOR or similar software.

Certificates and Licenses: Must possess a valid driver's license

ASQ Certified Quality Process Analyst or equivalent certification preferred

Six Sigma Green Belt – Black Belt preferred

Completion of CPI Certificate Program or similar training in continuous process improvement

Supervisory Responsibilities: This job has no supervisory responsibilities

Safety: Must comply with and follow all IE standards, programs, policies, and procedures as they apply to this position, reports any unsafe condition immediately. Must operate and perform job duties in a safe manner. Must be able to operate/work safely around machinery/moving equipment.