Lean Manufacturing Engineer

Position Summary

US Modules is seeking a driven and hands-on Lean Manufacturing Engineer to support continuous improvement initiatives across our solar module manufacturing operations. This role is responsible for identifying waste, improving production efficiency, optimizing material flow, and driving a culture of operational excellence throughout the factory.

The Lean Engineer will partner closely with Production, Quality, Maintenance, Supply Chain, and Engineering teams to improve throughput, reduce costs, increase yield, and support safe, scalable manufacturing processes for photovoltaic (PV) module production.

Key Responsibilities

• Lead Lean Manufacturing and Continuous Improvement initiatives across solar module production lines.
• Analyze manufacturing workflows to reduce cycle time, scrap, downtime, and non-value-added activities.
• Facilitate Kaizen events and continuous improvement workshops.
• Develop and maintain KPIs related to OEE, productivity, yield, labor efficiency, and waste reduction.

Apply Lean tools and methodologies including:

• Value Stream Mapping (VSM)
• 5S
• Kaizen
• Standard Work
• SMED
• Root Cause Analysis
• Visual Management
• Kanban
• Poka-Yoke

Partner with Production and Process Engineering teams to optimize:

• Cell stringing

• Lamination

• Framing

• Junction box installation

• Final assembly

• Testing and packaging processes

• Support line balancing, capacity analysis, and bottleneck reduction efforts.

• Implement visual factory systems and sustain 5S standards throughout manufacturing areas.

• Conduct time studies and process observations to identify opportunities for improvement.

• Assist in developing standard operating procedures (SOPs) and work instructions.

• Train employees on Lean principles and continuous improvement methodologies.

• Support new equipment launches and process transfers with Lean design principles.

• Collaborate with Quality teams to reduce defects and improve first-pass yield.

• Participate in safety initiatives and ensure Lean improvements align with EHS standards.

Qualifications

Required

• Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or related field.
• 3+ years of Lean Manufacturing or Continuous Improvement experience in a manufacturing environment.
• Strong knowledge of Lean, Six Sigma, and operational excellence methodologies.
• Experience with data analysis, process mapping, and KPI reporting.
• Strong problem-solving and facilitation skills.
• Proficiency in Microsoft Excel, Power BI, or similar analytical tools.
• Excellent communication and cross-functional collaboration skills.

Preferred

• Experience in solar, semiconductor, electronics, automotive, or high-volume manufacturing.
• Lean Six Sigma Green Belt or Black Belt certification.
• Familiarity with photovoltaic (PV) module manufacturing processes.
• Experience with MES, ERP, and manufacturing data systems.
• Knowledge of automation and Industry 4.0 concepts.

Key Performance Indicators (KPIs)

• OEE improvement
• Scrap and defect reduction
• Throughput increase
• Labor productivity
• Downtime reduction
• Inventory reduction
• 5S audit performance
• Kaizen implementation success
• Cost savings generated

Work Environment

• Manufacturing plant environment with exposure to automated production equipment.
• Frequent time spent on production floor supporting operators and supervisors.
• May require occasional travel to suppliers or other manufacturing sites.

Preferred Competencies

• Continuous improvement mindset
• Strong analytical thinking
• Change management capability
• Ability to influence teams without direct authority
• Results-oriented and hands-on approach
• Strong organizational and project management skills

Work Environment

This is an on-site role requiring daily presence on the manufacturing floor. The position involves working around automated equipment and production processes. PPE is required, with flexibility to support off-shift production needs during ramp-ups or critical events.