Continuous Improvement Engineer

Continuous Improvement Engineer

The Continuous Improvement Engineer is responsible for ensuring product quality through robust, repeatable manufacturing processes while driving continuous improvement initiatives across the operation. This role combines quality assurance, process engineering, and Lean Manufacturing to enhance product consistency, reduce defects, and improve overall operational efficiency.

The Quality Engineer will lead root cause analysis and corrective actions, and partner cross-functionally with Production, Quality, Engineering, Supply Chain, and global teams to standardize and improve processes. This role plays a key part in fostering a culture of continuous improvement throughout the organization.

Key Responsibilities

• Lead root cause analysis (RCA) and corrective/preventive action (CAPA) processes for internal defects, customer complaints, and nonconforming materials.
• Drive continuous improvement initiatives using Lean Manufacturing tools such as:
• Value Stream Mapping (VSM)
• Kaizen Events
• 5S & Visual Management
• Standardized Work
• Identify and implement process improvements to reduce waste, improve flow, and increase process capability.
• Utilize structured problem-solving methodologies (A3, 5-Why, Fishbone) to eliminate recurring issues.

Quality Assurance & Systems

• Develop, implement, and maintain quality control plans, inspection methods, and process controls to ensure product specifications and customer requirements are met.
• Establish critical control points, monitoring methods, and reaction plans to ensure process stability and repeatability.
• Conduct layered process audits, product audits, and system audits to ensure compliance with production standards, quality standards, and regulatory requirements.

Process Engineering & Data Analysis

• Analyze production and quality data to identify trends, variation, and improvement opportunities.
• Apply statistical tools and methods including:
• Statistical Process Control (SPC)
• Process Capability (Cpk/Ppk)
• Design of Experiments (DoE)
• Develop dashboards and reports to communicate quality performance and improvement progress to leadership.
• Monitor KPIs related to scrap, defects, yield, and customer performance.

New Product Introduction & Risk Management

• Support new product launches by implementing risk mitigation strategies using tools such as:
• Design FMEA (DFMEA)
• Process FMEA (PFMEA)
• Control Plans
• Collaborate with Engineering and Innovation teams to ensure manufacturability and quality readiness.

Training, Culture & Leadership

• Train and mentor production teams on continuous improvement methodologies.
• Promote a culture of operational excellence.
• Engage cross-functional teams in problem-solving and continuous improvement efforts.

Global Quality Alignment

• Collaborate with global teams to align processes, standards, and best practices across regions.
• Act as a regional representative to ensure consistency in systems, metrics, and execution.
• Support global initiatives related to system improvements and capability development.

Qualifications

• Bachelor's degree in Engineering, Manufacturing, Quality, or related field (or equivalent experience).
• 3–5+ years of experience in a manufacturing environment with a focus on quality and process improvement.
• Strong knowledge of Quality Management Systems (QMS), including ISO 9001.
• Experience with Lean Manufacturing and continuous improvement methodologies.
• Proficiency in statistical tools and problem-solving methods (SPC, Cpk, DoE, RCA, CAPA).
• Experience with ERP systems and Microsoft Office (Excel, PowerPoint, Word).
• Strong analytical, problem-solving, and decision-making skills.
• Excellent communication and cross-functional collaboration skills.

Vibram is a growth company seeking motivated individuals to grow with it. We offer a supportive work environment, professional development, and a collaborative culture.

Vibram is committed to diversity and inclusion in our workforce. Qualified applicants will receive consideration without regard to race, color, religion, sex, national origin, age, sexual orientation, gender identity, gender expression, veteran status, or disability.