Continuous Improvement Engineer

About the Role

The Continuous Improvement Engineer drives operational excellence by identifying, developing, and implementing process improvement initiatives across manufacturing operations. This role partners with production, safety, engineering, quality, and supply chain teams to optimize processes, reduce waste, improve productivity, and enhance product quality. The CI Engineer leverages Lean, Six Sigma, and other continuous improvement methodologies to implement sustainable solutions, monitor performance, and standardize best practices across operations.

Responsibilities

• Work closely with production team members to understand their perspective, listen to challenges, and implement solutions.
• Lead efforts to create an efficient, zero-defect environment.
• Facilitate communication with other departments to innovate systems of efficiency and improvement.
• Promote a culture of continuous improvement and operational excellence across the organization.
• Identify opportunities to improve efficiency, reduce waste, and enhance process capability using Lean, Six Sigma, and other CI tools.
• Conduct process mapping, value stream analysis, and root cause analysis to diagnose inefficiencies and implement solutions.
• Develop strategies to maximize development processes for new products and prototypes.
• Support pilot programs, process trials, and prototype production runs to validate process changes.
• Analyze systems and processes and implement value stream mapping.
• Identify areas to maximize value, including inventory, downtime, scrap utilization, and time management.
• Lead and manage continuous improvement projects from concept through implementation.
• Develop project plans, charters, KPIs, and timelines, ensuring alignment with operational and business goals.
• Facilitate Kaizen events, cross-functional problem-solving sessions, and process improvement workshops.
• Track project progress, evaluate results, and communicate outcomes to stakeholders.
• Collect, analyze, and interpret operational, quality, and production data to drive process improvement decisions.
• Monitor KPIs such as OEE, cycle time, scrap rates, downtime, and first-pass yield.
• Prepare dashboards, reports, and presentations to communicate impact to management and teams.
• Work cross-functionally with engineering, production, maintenance, safety, and quality teams to implement improvements.
• Train and mentor team members on CI principles, Lean tools, and problem-solving techniques.
• Ensure process improvements comply with quality standards (IATF 16949, ISO 9001) and safety regulations (OSHA, EPA).
• Support ergonomic assessments and implement safety improvements during process changes.

Requirements

• Bachelor’s degree in Industrial, Manufacturing, Mechanical, Electrical Engineering, or a related field.
• 3–5 years of experience in manufacturing, process improvement, or continuous improvement roles.
• Strong knowledge of Lean Manufacturing, Six Sigma, Kaizen, 5S, and other continuous improvement methodologies.
• Fundamentals of fixture and tool design.
• Experience conducting root cause analysis, process mapping, and value stream analysis.
• Proficiency in Microsoft Office Suite (Excel, Word, PowerPoint) and basic data analysis tools.
• Excellent problem-solving, project management, and written and verbal communication skills.

Preferred Qualifications

• Lean Six Sigma Green Belt or Black Belt certification.
• Experience in automotive or low-volume high-mix manufacturing environments.
• Familiarity with ERP/MES systems, SPC tools, and process simulation software.
• Experience mentoring and leading cross-functional teams.
• Knowledge of safety and quality compliance standards.

Tools

Required:

• Microsoft Office Suite (Excel, Word, PowerPoint)
• Lean/Six Sigma tools (Value Stream Mapping, 5 Whys, Fishbone Diagram, etc.)
• SPC and data analysis tools
• Project management software (MS Project, Smartsheet)

Preferred:

• ERP/MES systems (SAP, Oracle)
• CAD/SolidWorks or manufacturing simulation software
• Dashboard and KPI reporting tools

Physical Requirements

• Prolonged periods sitting at a desk and working on a computer.
• Must be able to lift up to 50 pounds occasionally.
• Ability to visually inspect and interpret designs on screen and in print.
• Use of functional Core Tools.
• Requires the ability for close vision, distance vision, and depth perception.
• Requires working and interacting with others, both in person and through phone, electronic, and written correspondence.
• Requires the ability to listen effectively, communicate clearly, maintain attention to detail, and perform focused work.
• Motions required during the day: standing or sitting for extended periods, stepping up & down, balancing, bending (hip & knees), reaching, standing, walking, pulling, pushing, lifting (from floor to waist, waist to chest, chest to head), observing, hearing, grasping, pressing, and other repetitive actions.
• When in the warehouse, this position requires working with dirt/dust and noise. The use of a variety of proper PPE is required to provide a safe working environment.
• Requires working with various temperature conditions.
• May require travel.

Schedule

This work is deadline-oriented, requires multitasking, fluctuating work schedule, and flexibility within the workday. Frequent use of a computer and other office equipment is necessary.

FLSA Status: Salaried Exempt (subject to review based on actual job duties and compensation).