Production Improvement Specialist

Position Summary

The Production Improvement Expert is responsible for analyzing, optimizing, and continuously improving production processes to increase efficiency, quality, safety, and cost-effectiveness. This role works closely with production, engineering, quality, maintenance, and supply chain teams to identify opportunities for operational excellence and drive sustainable improvements.

Principal Activities

• Providing hands-on technical support for chronic production problems involving welding, manual machining, CNC machining, setup, tooling, workholding, fixturing, and process execution.
• Partnering with the Industrial Engineer and Manufacturing / Methods Engineer to develop, test, validate, and sustain improved manufacturing methods.
• Analyze production processes, workflows, and performance metrics to identify improvement opportunities.
• Lead continuous improvement projects using methodologies such as Lean Manufacturing, Six Sigma, Kaizen, and Total Productive Maintenance (TPM).
• Develop and implement strategies to improve productivity, quality, throughput, and equipment effectiveness.
• Conduct root cause analysis for production issues and implement corrective and preventive actions.
• Monitor key performance indicators (KPIs) including yield, scrap rates, downtime, and cycle times.
• Collaborate with cross-functional teams to implement process improvements and standard operating procedures.
• Support automation and digital transformation projects where applicable.
• Train and coach employees on continuous improvement tools and best practices.
• Ensure compliance with safety, environmental, and quality standards.
• Prepare reports and presentations on improvement initiatives, results, and cost savings.

Technical Focus Areas

• Welding Process Improvement:
• Support improvement of welding processes, techniques, tooling, fixtures, sequencing, and work aids.
• Provide practical welding expertise during root cause analysis, process development, and improvement activities.
• Support development and improvement of weld methods that increase quality, repeatability, and efficiency.
• Partner with Materials Engineering and Quality on welding procedure development, welder performance considerations, audits, and compliance-related improvement needs.
• Provide input on welding equipment, consumables, workholding, process controls, and advanced welding technologies where applicable.
• Support technical troubleshooting for difficult welds, nonferrous materials, hardfacing/cladding, distortion, accessibility, fit-up, and repeatability challenges.
• Manual Machining Process Improvement:
• Support improvement of manual machining methods, setup practices, workholding, tooling, inspection points, and operator work aids.
• Help identify opportunities to improve repeatability, reduce rework, improve safety, and simplify execution for manual machining operations.
• CNC Machining Process Improvement:
• Support improvement of CNC machining processes through practical evaluation of setup, tooling, fixturing, machine behavior, program execution, operator interaction, and process stability.
• Partner with Manufacturing / Methods Engineering, CNC programming, and Production to troubleshoot recurring CNC machining issues.
• Provide input on manufacturability, setup reduction, tool selection, workholding, inspection integration, and cell layout for complex machined components.
• Support process improvement efforts for complex stems, plugs, seats, bodies, and other critical valve components.
• Tooling, Workholding, and Fixture Improvement:
• Aid in the design, build, modification, and implementation of tooling, fixtures, work aids, and setup aids required to improve process performance.
• Identify practical methods to reduce setup variation, improve repeatability, reduce handling risk, improve ergonomics, and make correct execution easier.
• Support evaluation of tooling and fixture performance during production trials and improvement projects.

Candidate Requirements

• Knowledge, Skills & Abilities:
• Working knowledge of manufacturing operations, production workflows, operational excellence, quality systems, safety requirements, and performance management in a production environment.
• Ability to analyze production processes, workflows, constraints, and performance metrics to identify opportunities for improvement.
• Ability to develop, lead, and implement improvement initiatives that increase productivity, quality, throughput, safety, cost-effectiveness, and equipment effectiveness.
• Strong analytical and problem-solving skills, including the ability to conduct root cause analysis, evaluate data, identify trends, and implement sustainable corrective actions.
• Ability to monitor, interpret, and report on key performance indicators, including yield, scrap rates, downtime, cycle times, throughput, and other operational metrics.
• Strong project management skills, including the ability to plan, organize, prioritize, execute, and follow through on multiple improvement projects.
• Ability to develop, implement, and sustain standard operating procedures, standard work, process controls, and best practices.
• Ability to support automation, digital transformation, data collection, and process visibility initiatives where applicable.
• Strong communication and presentation skills, including the ability to prepare reports, present improvement results, communicate cost savings, and explain technical or operational concepts clearly.
• Proficiency with Microsoft Office applications, data analysis tools, ERP/MRP systems, production reporting systems, or other business systems used to track and improve operational performance.
• Ability to demonstrate ownership, accountability, teamwork, and a continuous improvement mindset in support of operational excellence and first-time quality.
• Preferred Technical Experience:
• Experience in complex, low-volume / high-mix manufacturing.
• Experience with valve manufacturing or similarly complex precision mechanical products.
• Strong background in one or more of the following: welding, manual machining, CNC machining, toolmaking, fixture development, manufacturing troubleshooting, or production process improvement.
• Practical knowledge of welding processes such as GTAW, SMAW, GMAW, hardfacing, cladding, or hot-wire GTAW.
• Familiarity with difficult-to-weld or difficult-to-machine materials, including nonferrous alloys, nickel alloys, copper-nickel, nickel-copper, cobalt-chrome, aluminum bronze, or similar materials.
• Familiarity with CNC machining, manual machining, turning, milling, boring, grinding, or other precision manufacturing processes.
• Familiarity with military, Navy, nuclear, aerospace, or similarly strict quality and documentation environments.
• Experience supporting tooling, fixture, workholding, setup reduction, or manufacturing cell improvement efforts.
• Familiarity with weld procedure qualifications, welder performance qualifications, welding audits, or weld compliance requirements is a plus.
• AWS CWI, welding certifications, machining credentials, toolmaker experience, or equivalent demonstrated technical expertise is a plus.
• Education and Experience:
• Minimum of 10 years of hands-on manufacturing experience in welding, machining, tooling, manufacturing troubleshooting, or production process improvement.
• Experience in a complex manufacturing environment with strict quality, safety, documentation, and customer requirements preferred.
• Equivalent combinations of technical training, certifications, and hands-on experience may be considered.