OpEx and Industrial Engineer Specialist

Location: Flora, IL

About the role

FORVIA HELLA is a listed international automotive supplier. As a company of the FORVIA Group, FORVIA HELLA stands for high-performance lighting technology and vehicle electronics and, with the Lifecycle Solutions Business Group, also covers a broad service and product portfolio for the spare parts and workshop business as well as for manufacturers of special vehicles. With currently around 34,000 employees at over 125 locations worldwide, the company generated adjusted sales of €8.0 billion in the fiscal year 2025.

Responsibilities

• Apply continuous improvement techniques and methodologies in the production environment such as Lean Manufacturing, Six Sigma, and KPI establishment to reduce waste and improve productivity.
• Develop, implement, and lead initiatives for operational excellence (OpEx) including improvement projects and standardization of best practices across the organization.
• Analyze the effectiveness of existing operational processes and systems, highlighting areas for improvement and initiating appropriate actions to implement changes.
• Collaborate with cross-functional teams to drive and implement process improvements, ensuring that root causes are addressed and that measurable improvements in performance are achieved.
• Conduct capacity utilization studies and production flow analyses to identify areas of potential efficiency improvements.
• Design layout of facilities, equipment, and offices for maximum efficiency, safety, and regulatory compliance for both existing and new production lines.
• Conduct training sessions on the principles of OpEx and lean manufacturing for both team members and management, and support the change management process.
• Utilize advanced modeling and analysis tools to develop end-to-end supply chain network models that accurately reflect cost structures and resources impacting performance.
• Develop standardized process measurement tools to monitor consistency and predictability of operations.
• Manage and execute projects to reduce costs, improve service, and enhance customer satisfaction.
• Perform regular audits of the process control system to ensure adherence to compliance and efficiency guidelines.
• Ensure environmental, safety, quality, and health standards and regulations are complied with at all times.

Requirements

• Minimum of 5 years' experience in operations, manufacturing engineering, process improvement, or a similar role.
• Strong working knowledge of Lean Manufacturing principles, Six Sigma methodologies, and operational excellence (OpEx) is a must.
• Professional certification such as Lean Six Sigma Black Belt or Green Belt is highly desirable.
• Strong analytical skills with demonstrated problem-solving ability.
• Excellent project management skills with the ability to lead cross-functional teams and manage multiple projects simultaneously.
• Excellent verbal and written communication skills with the ability to present complex information in a clear and concise manner to a variety of audiences.
• Proficient in the use of statistical analysis software, CAD/CAM, and MS Office Suite.
• Knowledge of manufacturing process controls and quality assurance methodologies.
• Experience in supply chain management, logistics, or a similar field is advantageous.
• Demonstrated ability to design, develop, and implement systems for tracking operational metrics and improving processes.
• Awareness of health, safety, and environmental regulations.
• Must be a self-starter with the ability to work independently as well as part of a team.
• Ability to travel to various sites as required.

Pay

Starting Salary Range: $62,000–$65,000.