Continuous Improvement Engineer

BP; United States; On-site; USD 90,000 - 130,000; Full time

Job summary

TravelCenters of America is seeking a Continuous Improvement Engineer to lead operational excellence initiatives through process mapping, data analysis, and root-cause investigations. You will identify high-impact opportunities, design scalable solutions, and mentor teams in Lean Six Sigma and engineering practices.

You will drive enterprise-wide improvement plans, partner with senior leadership to align initiatives with strategic goals, and influence multi-functional teams to sustain gains in

Qualifications

• 5+ years of related experience in continuous improvement, process engineering, or operations.
• Experience with Standard Work, Visual Management, PDCA, and Kaizen Events.
• Strong analytical, facilitation, and stakeholder management skills.
• Proficiency in data analysis, dashboards, and reporting tools.

Responsibilities

• Conduct process mapping, data analysis, and root cause analysis to identify inefficiencies and areas for improvement.
• Independently identify process gaps and design scalable solutions across sites or functions.
• Develop and lead enterprise-wide improvement plans delivering measurable results in safety, quality, delivery, cost, and development.
• Lead complex, multi-functional projects using Lean, Six Sigma, and related methodologies.

Skills

Lean Six Sigma

Process engineering

Data analysis

Stakeholder management

Microsoft Office

Education

Bachelor's degree in Engineering or related field

Tools

Power BI

Minitab

SQL

VBA

AutoCAD

Job description

Job Family Group:

Engineering Group

Job Description:

Job Summary

As a Continuous Improvement Engineer at TravelCenters of America, you will use process mapping, data analysis, and root cause analysis to identify and lead central initiatives to drive operational excellence. You'll identify high-impact opportunities, design scalable solutions, and mentor others in Lean, Six Sigma, and engineering practices. This role demands strategic ownership, thinking big, acting decisively, and taking full accountability for meaningful change, along with the ability to influence and inspire multi-functional teams. Success in this role hinges on your knowledge of data analytics, engineering techniques, and advanced lean six sigma tools, as well as your business acumen and ability to connect operational improvements to customer experience and financial performance. You'll thrive in a fast-paced environment, adapt quickly to shifting priorities, and build strong multi-functional relationships to ensure improvements are sustained and aligned with long-term goals.

Key Responsibilities

Strategic Process Leadership

• Conduct process mapping, data analysis, and root cause analysis to identify inefficiencies and areas for improvement.
• Independently identify process gaps and systemic issues and design scalable solutions that enhance performance across multiple sites or functions.
• Develop, prioritize, and lead an enterprise-wide comprehensive improvement plan that delivers measurable results in safety, quality, delivery, cost, and employee development.
• Partner with senior leadership to align improvement efforts with strategic priorities and long-term goals.

Advanced Project Management

• Lead and facilitate complex, multi-functional projects using Lean, Six Sigma, and other methodologies to drive improved business results.
• Manage project portfolios, ensuring timely execution, stakeholder alignment, and sustained impact.
• Support launch and stabilization phases, ensuring solutions are embedded and continuously improved.

Engineering & Lean Expertise

• Apply advanced engineering tools (e.g., simulation modeling, layout optimization, labor standards, time studies, resource modeling, quality standards) to drive efficiency.
• Identify and support opportunities for automation implementation within new and established processes.
• Serve as a subject matter expert in Lean Six Sigma, coaching teams and developing internal capabilities to sustain CI, Quality Assurance and Lean Six Sigma principles across the organization.
• Effectively facilitate and execute Value Stream Maps and Kaizen Events through all stages (charter ideations/creation, pre-work identification and completion, regular follow-up, and sustainment).
• Apply engineering methodologies/tools such as process optimization, labor standards studies (time studies), layout optimization, data profiling and analysis, and resource modeling to improve Truck Service field and support center operations.

Customer & Business Impact

• Apply advanced data analysis to analyze customer feedback and operational data to identify trends and solution improvement opportunities that enhance experience and performance.
• Provide regular executive level reporting of data and actions to measure progress against site objectives. Make data driven optimization recommendations that align with Truck Service strategy.

Additional Responsibilities

• Implement and monitor standardized corrective action systems.
• Support safety, risk, and compliance initiatives, prioritizing the "Believe in Zero" safety philosophy.
• Perform other duties as assigned to support the continuous improvement mission.

What We'd Like to See

• Bachelor's degree in Engineering, Business Administration, or related field preferred; equivalent experience considered.
• 5+ years of related experience in a continuous improvement, process engineering, or operations function in a similar industry.
• Experience in developing and managing Standard Work, Visual Management Systems, Management Accountability Systems, Plan-Do-Check-Act (PDCA), Value Stream Mapping, Kaizen Event, Lean Six Sigma Projects and 5S/Workplace Organization.
• Intermediate understanding and experience in core engineering and data analysis functions such as slotting, utilization, labor planning, layouts and metrics.
• Strong analytical, facilitation, and stakeholder management skills.
• Proficiency in Microsoft Office Suite
• Experience with advanced engineering tools, data visualization platforms, and database programming (e.g., Power BI, Minitab, AutoCAD, Labor Management Systems, SQL, VBA)
• Knowledge of truck service operations, data analytics, industrial engineering and Lean Six Sigma methods.
• Understanding of maintenance and repair solutions and automation types, etc.
• Familiar with fleet management, vehicle maintenance operations, managed transportation networks, and various equipment types (trucks, tractors, trailers).
• Travel requirement is approximat