Process Improvement Engineer (USI7)

About the role

The Process Improvement Engineer will lead initiatives aimed at improving operational efficiency, reducing costs, and enhancing customer satisfaction. This role focuses on improving turnaround time (TAT), throughput, quality, and cost efficiency while ensuring strict compliance with FAA/EASA Part 145 and OEM requirements. A strong understanding of shop-level operations, test systems, and component-level workflows is required.

Responsibilities

• Review discrepancies between technical data and part condition, ensuring compliance and accuracy.
• Track, analyze, and report on non-conformances, using data to identify trends and areas for improvement.
• Lead root cause analysis to address process-related issues, developing and recommending corrective actions.
• Implement corrective actions and continuously monitor the impact to ensure long-term effectiveness.
• Create and update work instructions, including part routings and operation sheets, to reflect process improvements.
• Effectively communicate corrective action plans, progress, and results to stakeholders at all levels within the organization.
• Research and implement innovative technologies and processes to enhance company capabilities and drive innovation.
• Serve as a liaison with vendors, suppliers, and customers to support continuous improvement efforts.
• Analyze end-to-end component repair workflows (receiving, teardown, inspection, repair, assembly, test, and release).
• Identify bottlenecks in shop processes such as teardown, piece-part repair, and test stand utilization.
• Improve test stand utilization (automation), capacity planning, and scheduling efficiency.
• Perform root cause analysis (RCA) on failures, repeat discrepancies, and no-fault-found (NFF) events.
• Develop and maintain process maps, routing structures, and standard work instructions.
• Collaborate with engineering, quality, and technicians.
• Support implementation and optimization of MRO systems (e.g., ERP, MES, TRAX, AMOS, SAP).
• Ensure all improvements comply with FAA/EASA regulations and OEM manuals (CMMs).
• Track KPIs such as TAT, first-pass yield (FPY), test yield, and labor efficiency.
• Support the culture of continuous improvement by mentoring and coaching teams on Lean principles and methodologies.
• Other duties as assigned.