Continuous Improvement Specialist

Continuous Improvement Specialist

The Continuous Improvement Specialist is a hands-on, site-based individual contributor responsible for facilitating kaizen events, leading structured problem-solving initiatives, tracking and managing continuous improvement projects, and implementing process improvements directly on the production floor. This role will work across plastic injection molding, assembly, and paint operations to drive measurable improvements in safety, quality, delivery, and cost within an AS9100-certified aerospace manufacturing environment. The Continuous Improvement Specialist will be highly visible and accessible on the shop floor, collaborating with cross-functional teams including operations, quality, and engineering to translate Lean and Six Sigma concepts into practical, sustainable, operator-level execution.

Essential Duties and Responsibilities

Facilitate Continuous Improvement Activities: Lead and facilitate kaizen events, improvement workshops, and Gemba walks to eliminate waste, reduce process variation, and improve flow across molding, assembly, and paint operations.

Lead Structured Problem Solving: Facilitate cross-functional problem-solving activities using A3 methodology, 5-Why analysis, root cause corrective action (RCCA), and fishbone diagrams to address quality issues, process inefficiencies, and customer concerns.

Implement Improvements On-Site: Implement improvements hands-on at the site, working directly with operators, supervisors, and team leads to ensure changes are practical, operator-friendly, and embedded into daily work.

Track and Manage CI Projects: Track and manage multiple continuous improvement projects simultaneously using CI project tracking or management system, ensuring alignment with site strategic objectives and timelines.

Analyze Process and Quality Data: Analyze production, quality, and process data (e.g., nonconformities, scrap, rework, cycle times, equipment downtime, audit findings) to identify trends, root causes, and priority improvement opportunities.

Develop and Monitor KPIs: Develop and track key performance indicators (KPIs) for process performance and operational effectiveness, including First Pass Yield (FPY), on-time delivery (OTD), defects per unit, scrap rates, and CAPA cycle time.

Conduct Value Stream Mapping: Conduct Value Stream Mapping exercises to identify waste, bottlenecks, and non-value-added activities across molding, assembly, and paint processes.

Develop Standard Work: Develop and implement standard work, visual management systems (6S), and process controls to reduce variation and improve consistency.

Support AS9100 Quality Management System: Partner with Quality, Manufacturing, Engineering, and Supply Chain to ensure improvement actions support AS9100 Quality Management System (QMS) requirements and are embedded in processes for long-term sustainability.

Participate in Corrective Action Processes: Support corrective and preventive action (CAPA) processes, participating in root cause investigations and ensuring effectiveness of corrective actions.

Standardize Best Practices: Standardize and document best practices, lessons learned, and improved methods, supporting deployment across departments and ensuring compliance with aerospace quality and regulatory requirements.

Provide Training and Coaching: Provide training and coaching to employees and leaders on Lean Six Sigma tools, continuous improvement methodologies, and problem-solving techniques.

Support New Product Introduction (NPI): Facilitate continuous improvement activities for new product introduction (NPI) programs, ensuring processes are optimized from launch.

Collaborate Cross-Functionally: Work collaboratively with operations, quality, engineering, and supply chain teams to drive improvements, break down silos, and enable teamwork.

· Problem Solving. Uses rigorous logic and methods to solve difficult problems with effective solutions; probes all fruitful sources for answers; can see hidden problems; is excellent at honest analysis; looks beyond the obvious and does not stop at the first answers.

· Drive for Results. Can be counted on to exceed goals successfully; is constantly and consistently one of the top performers; very bottom-line oriented; steadfastly pushes self and others for results.

· Interpersonal Savvy. Relating openly and comfortably with diverse groups of people.

· Influencing Without Authority. Builds consensus and drives change through collaboration; can effectively influence and coach employees at all levels without direct supervisory authority.

· Continuous Improvement Mindset. Demonstrates passion for continuous improvement and dissatisfaction with the status quo; motivated to pursue positive change; exhibits curiosity and a learning orientation.

· Attention to Detail. Detail-oriented with strong organizational skills; able to manage multiple priorities and projects simultaneously.

· Customer Service Orientation. Focuses on meeting the needs of internal customers (operations teams) and external aerospace customers.

· Hands-On Approach. Action-oriented and comfortable working directly on the shop floor in manufacturing environments; spend significant time on the production floor observing, engaging, and identifying improvement opportunities.

· Adaptability. Able to work in high-paced and changing manufacturing environments; flexible and resilient in the face of obstacles.

· Analytical Thinking. Skilled at synthesis and analysis; able to translate complex data into actionable insights.

· Responsible to follow and ensure compliance with all established Vaupell policies, standard operating procedures, and safety practices.

· Other duties as assigned.

Job Qualifications/Requirements

Experience: 2–4 years of experience in continuous improvement, Lean manufacturing, manufacturing engineering, or quality improvement roles, preferably in aerospace or other regulated manufacturing environments.

Education: Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, Quality, Operations Management, or related technical field; or equivalent combination of education and manufacturing experience.

Continuous Improvement Expertise: Hands-on experience facilitating kaizen events, leading improvement workshops, and driving cross-functional process improvements using Lean methodologies.

Problem-Solving: Proven experience with A3 problem solving, root cause analysis (5-Why, fishbone/Ishikawa), and corrective action methodologies.

Six Sigma Green Belt (Minimum): Six Sigma Green Belt certification (minimum) with practical application of DMAIC and data-driven decision making.

Lean Tools & Methods: Experience with Value Stream Mapping, standard work, visual management, 6S, Gemba walks, and waste identification.

Quality System Knowledge: Working knowledge of AS9100 and/or ISO 9001 requirements, particularly corrective action, continual improvement, and process standardization.

Manufacturing Knowledge:: Understanding of manufacturing processes; experience with plastics injection molding, assembly, and paint/coating operations preferred.

Communication Skills: Strong communication, facilitation, and training skills with the ability to work effectively across all levels of the organization.

Candidates must be a "US Person" (i.e., US Citizen or Permanent Resident) to ensure Vaupell's compliance with ITAR (International Traffic in Arms Regulations) and EAR (Export Administration Regulations).

Environmental Condition

While performing the duties of this job, the employee is frequently exposed to moving mechanical parts. The employee is occasionally exposed to fumes, airborne particles, and vibrations. The noise level in the work environment is usually moderate to occasionally loud. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Physical Requirements

This position requires a combination of office and manufacturing floor environment work. The employee will spend significant time standing and walking on the production floor (40–60% of the workday) with regular sitting for documentation, analysis, and reporting (30–40%). Frequent use of hands and fingers is required for grasping, handling, keyboarding, and coordination, along with routine sensory demands including hearing and near/far vision, depth, and color perception. Occasional bending, reaching, turning/twisting, stair climbing, and lifting/carrying/pushing up to and over 50 lbs. may be required (20% or less).

Vaupell reserves the right to change, modify or add to the Essential Duties and Responsibilities of any position at any time.

Vaupell is an equal opportunity employer. All applicants will be considered for employment without attention to race, color, religion, belief and spirituality, gender, age, sexual orientation, gender identity or expression, ethnicity/national origin, pregnancy, genetic information, veteran, or disability status.