Continuous Improvement Process Engineer

Samuel, Son & Co.; Markham; On-site; CAD 94,000 - 105,000; Full time

Job summary

Samuel, Son & Co. in Markham, Ontario seeks a Process Engineer to lead lean initiatives across manufacturing lines. You will analyze processes to improve yield, reduce scrap, and boost OEE while ensuring safety and quality standards.

The role emphasizes data-driven problem solving, DMAIC, and cross‑functional collaboration with engineering, QA, and maintenance to sustain gains and standardize practices company-wide.

Qualifications

• Bachelor's degree in Industrial Engineering or a related field.
• 2-3 years Process Engineering experience in metal tube, aerospace or related industry preferred.
• Experience leading yield, OEE, SMED and production improvement projects.
• Strong analytical skills using Lean Six Sigma methodologies.

Responsibilities

• Improve process yield, scrap and efficiency through workflow analysis and layout planning.
• Lead time studies, capacity analysis and space optimization for flow improvements.
• Apply 8D, fault trees, 5 Whys and DoE for root cause and corrective actions.
• Prepare documentation for new manufacturing processes and trends reports.
• Assure product/process quality by testing capabilities and establishing standards.
• Determine root causes and recommend design/processing changes as needed.
• Collaborate with Management, Quality Assurance, CI and Maintenance to sustain gains.
• Support 5S, Kaizen and continuous improvement initiatives.

Skills

Lean Six Sigma

DMAIC

Data analysis

Problem-solving

Cross-functional collaboration

Education

Bachelor’s degree in Industrial Engineering

Tools

Excel

Power BI

SQL

Python

Tableau

AutoCAD

SolidWorks

Visio

Apollo

JDE

Job description

RESPONSIBILITIES AND PHILOSOPHY

• 1. Operator Development and Empowerment
  • Improve process yield, scrap, rework and manufacturing efficiency by analyzing the process and planning workflow, space requirements, and equipment layout. Coordinate input that may cross multiple teams or areas; make recommendations and implement changes.
  • Responsible for maximizing the following: (1) Cost Effectiveness; (2) Scrap Reduction; (3)Overall Equipment Effectiveness (OEE); (4) Single Minute Exchange of Die (SMED); (5) Mill Uptime and (6)Reliability towards manufacturing flow, processes and equipment.
  • Facilitates time studies, capacity analysis, space optimization, process lay‑outs to support the vision of flow and optimize cost through driving process efficiencies and value stream improvements with the value stream.
  • Assist in technical input to perform corrective actions using 8-D format, fault trees, cause & effect diagrams, 5 Whys, A3, Design of Experiment and other tools; and to communicate data internally and externally.
  • Participates in the AS9100/ISO9001/IATF quality management system requirements Refine and enhance processes by applying continuous improvement and key Lean manufacturing/production principles and techniques to areas of production. Recommend product changes/improvements.
  • Identify and implement solutions for issues relating to safety, quality, productivity, and cost reductions.
  • Develop innovative solutions to complex manufacturing production problems through identification and implementation of advanced manufacturing processes including conducting process analysis, applying knowledge of product design and materials, and soliciting observations from the operators/production technicians.
  • Prepare documentation for new manufacturing processes.
  • Prepare reports summarizing analyzed process information and trends.
  • Assure product and process quality by testing process capabilities and establishing standards to confirm and validate manufacturing process requirements.
  • Determine root cause of failures using statistical methods (e.g., design of experiment, SPC) that may result in recommended changes in design, tolerances, or processing methods.
• 2. Active Gemba and Process Robustness
  • Support the VSM, lead hands, operators and transactional support groups in recovery and preventive actions for rework, setup, and changeovers.
  • Application of Lean Six Sigma Methodologies (DMAIC, DMADV)
  • Use the necessary lean tools, supplies and guidance to improve effectiveness.
  • Reinforce (1)5S; (2)Idea Management; (3)Time Studies, (4)Space optimization, (4)Kaizen, (5)Kanban, (6)Hoshin Kanri, (7)Poka-Yoke; (8) SIPOC; (9)SMED; (10)Obeya; (11)Leader Standard Work; (12)Gemba and (13)Value Stream Mapping.
  • Collaborate with management to prioritize improvement efforts based on data, impact, and feasibility.
• 3. Behavioral and Process Analysis
  • Use pain point logs, cause-and-effect diagrams, 5 Whys, and other Lean Six Sigma tools to identify root causes at the real place (Gemba).
  • Application of Lean Six Sigma Methodologies (DMAIC, DMADV)
  • Facilitation of (1)Project Drilldown Analysis; (2)Project Charters; (3)8D; (4)A3; (5)Kaizen
• 4. Analytical and Technical Responsibilities
  • Collaborate with Management, Quality Assurance, Group Engineering, and other departments to execute and sustain improvements.
  • Must be proficient in applications used for documentation and data analysis including but not limited to: Excel, Word, PowerPoint, Visio, Power BI, SQL, Tableau, Python, AutoCAD, Solid Works, Apollo
  • Knowledge of JDE systems
• 5. Benchmarking & Standardization Framework
  • Internal Benchmark: Observe and assist operators to identify real issues, wastes, constraints and root causes.
  • Functional Benchmark: Research operational excellence relative to Process Engineering improvements across similar or divergent industries especially Tubing, Aerospace and Data Center.
• 6. Collaboration and Cross-Departmental Integration
  • Partner with VSM, QA, CI, Maintenance to ensure equipment robustness and reduce operator struggles.
  • Collaborate with Management and HR for alignment, morale, and training.
  • Support business expansion by improving employee engagement, process capability, compliance, and reducing Cost of Poor Quality (COPQ).
• 7. Apply Frameworks for Lean Quick Wins
  • Empower operators to stop the process when issues occur. Build quality at the source by reacting immediately to defects instead of passing them downstream.
  • Foster an environment where learning, feedback, and small daily improvements are celebrated. Encourage continuous experimentation and adaptation.
  • Simplify complex concepts by explaining them in clear, everyday language. Use this method to teach operators and teams, ensuring true understanding.
• 8. Continuous Improvement Initiatives
  • Actively participates in the 5S Big Clean‑Up Activities and supports the ATC 5S Standardization.
  • Reinforce Value Stream Mapping Activities by providing updated VSM cycle time, standard time, mapping, SIPOC analysis.
  • Spearheads CI Projects related to Yield, Scrap, OEE, SMED, Mill Up‑time Projects.

OBJECTIVES

• Communicate with the Value Stream Managers, operators, lead hands, and QA/QC to understand ongoing issues and goals.
• Engages in the ATC TIBS Meeting and challenges the team on the OFI’s in the metrices in the TIBS relative to Safety, Quality, Delivery and Cost.
• Conduct gemba walks to observe operations, identify wastes, and record improvement opportunities.
• Act on Lean Quick Wins opportunities that are low cost, low effort but high impact improvements.
• Reinforce and supports 5S standards at workstations. Provide operators with proper tools and supplies to optimize preparedness and effectiveness.
• Engage operators in quick 5–10 minute micro‑learning moments to reinforce Lean principles.
• Provide support to maintenance when equipment issues impact robustness or productivity.
• Communicate process engineering improvement projects and status to management and relevant departments.
• Review log data and trends to identify recurring issues or variations.
• Meet with VSM, QA, Group Engineering, and Lean teams to align improvement priorities.
• Conduct Root Cause Analysis on one key recurring issue per week.
• Update Process Engineering KPI’s and reports related to Yield, Scrap, VSM, OEE, SMED, Mill Uptime
• Present a monthly improvement report summarizing:
  • Key projects completed or initiated (Refer to KPIs)
  • Quantified waste reduction and process improvements
• Lead or co‑lead a small‑to‑medium Lean improvement project with cross‑functional collaboration.
• Conduct internal benchmarking reviews to compare process capability and performance.
• Review and refresh training content for learning sessions.
• Supports and evaluates 5S, Idea Management, Kaizen sustainability and corrective measures for drift.
• Report PE Metrices trends and process stability metrics to management.
• Perform gap analysis to document our current status versus past performance, enabling measurable progress tracking.
• Facilitate projects assigned by management, forming cross‑functional teams of Yellow Belts and process owners to execute them collaboratively.
• Maintain continuous work to sustain all improvement initiatives and ensure gains are not lost.

JOB REQUIREMENTS

• Bachelor’s degree in Industrial Engineering or a related Engineering field.
• Proven 2-3 years of Process Engineering experience preferably in Metal Tube, Aerospace or other related industry.
• Spearheads Yield, VSM, Rework, Time Study Analysis, SMED, OEE, Scrap & Space Optimization Projects
• Strong analytical and Problem‑Solving skills utilizing Lean Six Sigma methodologies, 8D, 5 Why, Design of Experiment, etc.
• Knowledge of Lean, Six Sigma or other improvement methodologies. L6S GB or BB Certification.
• Data‑driven mindset with proficiency in data analysis tools. Must be able to use Excel, Word, PowerPoint, Visio, Power BI, SQL, Tableau, Python, AutoCAD, Solid Works, Apollo
• Has working knowledge of engineering domain principles and techniques, product functionality, industry practices, regulations, and policies. General knowledge of other related engineering and technical areas and the ability to analyze complex technical issues Excellent communication and interpersonal skills, with a customer‑focused mindset.
• Ability to work with general objectives regarding projects and team goals; applies judgment in selecting procedures and techniques that should be applied. Works collaboratively in a team environment.

HEALTH AND SAFETY

• Demonstrates a positive attitude towards safety and models safety for other employees at all times.
• Understand that it is mandatory to use and/or wear all personal protective equipment provided by the Company.
• Reports all accidents, incidents and near misses and supports in determining corrective actions to eliminate workplace hazards.
• Practices safe work habits as detailed in Samuels/ATC’s safety policies, procedures, C.S.A and the Occupational Health & Safety Act of Ontario.
• Understands and completes necessary health & safety training through Samuel’s Safety Training program and ensures renewal training is completed as per company requirements.

This is for a current open position. AI is not used in the screening of candidate resumes.

• The expected compensation range for this position is $93,840-$105,030. This range includes base pay and target variable pay. Actual compensation will depend on factors such as geographic location, skills, education, and experience. We also consider internal equity to ensure fair and consistent pay practices. This range reflects the expected full compensation range for the role; most offers will fall within the range and not at the maximum in order to allow for future growth.