Continuous Improvement (CI) Engineer III

AAF International (American Air Filter); Washington (NC); On-site; USD 80,000 - 110,000; Full time

Job summary

AAF International (American Air Filter) is seeking a Continuous Improvement Engineer to act as a process SME for manufacturing operations. The role focuses on stabilizing processes, driving Lean culture, and sustaining improvements through standard work, problem solving, data analysis, and ROI justification.

Responsibilities include leading cross-functional Kaizen events, applying Lean tools (5S, Kanban, takt time), and partnering with Operations, Engineering, Quality, Maintenance and Supply

Qualifications

• 4-6 years of experience in a manufacturing or industrial environment.
• Experience owning manufacturing processes and supporting process control and sustainment.
• Working knowledge of Lean manufacturing principles and tools.
• Understanding of industrial automation and its application to manufacturing improvement.
• Experience developing ROI and cost justification for improvements or capital projects.
• Effective communication skills and cross-functional collaboration.
• Ability to support cultural change with data-driven analysis and practical problem solving.

Responsibilities

• Serve as SME for assigned manufacturing processes and understand process flow, capability, constraints, and risks.
• Lead efforts to bring processes into statistical control using standard work, control plans, SPC, and visual management.
• Recommend and implement improvements to production processes, methods, and controls.
• Apply analytical and creative thinking to solve manufacturing problems and improve performance.
• Lead and facilitate Lean culture shift across the organization and act as a coach for Lean practices.
• Encourage employee engagement and ownership of continuous improvement at all levels.
• Partner with leaders to reinforce Lean behaviors, standard work, and routines.
• Help embed Lean thinking into daily management systems and decision-making.
• Utilize structured problem-solving methodologies (DMAIC, PDCA, Shainin Red X).
• Define problems, identify root causes, implement solutions, and establish sustainment controls.
• Support team-based problem-solving and knowledge sharing.
• Facilitate cross-functional Kaizen events and hands-on shop-floor involvement.

Skills

Lean principles

Structured problem solving

Data-driven analysis

Cross-functional collaboration

Change leadership

Communication

Education

Bachelor's degree in Mechanical or Industrial Engineering

Tools

MTM

Statistical Process Control (SPC)

Visual management

Job description

Description

The Continuous Improvement Engineer serves as a process subject matter expert (SME) for manufacturing operations and plays a key role in leading and supporting the shift toward a sustainable Lean culture. This position focuses on stabilizing processes, bringing them under control, and sustaining improvements over time through lean manufacturing, structured problem solving, data-driven analysis, collaboration, and the effective use of automation supported by ROI justification. Performs work under minimal supervision. Handles complex issues and problems and refers only the most complex issues to higher-level staff. Possesses comprehensive knowledge of subject matter. Provides leadership, coaching, and/or mentoring to a subordinate group.

Description

The Continuous Improvement Engineer serves as a process subject matter expert (SME) for manufacturing operations and plays a key role in leading and supporting the shift toward a sustainable Lean culture. This position focuses on stabilizing processes, bringing them under control, and sustaining improvements over time through lean manufacturing, structured problem solving, data-driven analysis, collaboration, and the effective use of automation supported by ROI justification. Performs work under minimal supervision. Handles complex issues and problems and refers only the most complex issues to higher-level staff. Possesses comprehensive knowledge of subject matter. Provides leadership, coaching, and/or mentoring to a subordinate group.

Requirements

Process Ownership & Continuous Improvement

• Serve as a process subject matter expert for assigned manufacturing processes, understanding process flow, capability, constraints, and risks.
• Lead efforts to bring processes into statistical control and sustain gains using standard work, control plans, SPC, and visual management.
• Recommend and implement improvements to production processes, methods, and controls.
• Apply analytical and creative thinking to solve manufacturing problems and improve performance.

Lean Culture & Change Leadership

• Lead, support, and facilitate the ongoing shift toward a Lean culture across the organization.
• Act as a coach and change agent by helping teams understand why Lean practices are used, not just how.
• Encourage employee engagement and ownership of continuous improvement at all levels.
• Partner with leaders and teams to reinforce Lean behaviors, standard work, and continuous improvement routines.
• Help embed Lean thinking into daily management systems and decision-making.
• Utilize at least one structured problem‑solving methodology, such as:
  • DMAIC
  • PDCA
  • Shainin Red X
• Define problems clearly, identify and validate root causes, implement effective solutions, and establish controls to sustain results.
• Support team-based problem‑solving activities and knowledge sharing.

Lean Manufacturing & Kaizen

• Apply lean manufacturing principles and tools, including:
  • 5S and visual workplace
  • Kaizen activities and events
  • Standard work
  • Kanban and pull systems
  • Takt time analysis, line balancing and line pacing
  • Waste identification and elimination
• Facilitate and participate in cross‑functional Kaizen events, recognizing the value of collaboration across Operations, Engineering, Quality, Maintenance and Supply Chain.
• Support continuous improvement through hands‑on involvement in shop‑floor activities.

Manufacturing Systems, Layout & Methods

• Plan, design, implement, and improve manufacturing systems that support performance, reliability, maintainability, schedule adherence, and cost control.
• Establish methods, equipment, and layouts for direct and indirect labor using time studies and predetermined time systems (e.g., MTM).

Knowledge/Experience

• 4-6 years of experience in a manufacturing or industrial environment.
• Experience owning manufacturing processes and supporting process control and sustainment.
• Working knowledge of Lean manufacturing principles and tools.
• Understanding of industrial automation and its application to manufacturing improvement.
• Experience developing or supporting ROI and cost justification for improvement or capital projects.
• Effective communication skills and comfort working cross‑functionally.
• Ability to support cultural change while balancing data‑driven analysis and practical problem solving.

Education Requirement

Bachelor’s degree in Mechanical Engineering , Manufacture Engineering, Industrial Engineering background or equivalent experience considered.

AAF International is an Equal Opportunity Employer M/F/Disability/Veteran.

We are an equal employment opportunity employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, sex, sexual orientation, gender identity, national origin, citizenship, veteran status, uniform servicemember status, age, disability or any other legally recognized protected personal characteristics.