Continuous Improvement Engineer

PPC Flex Company; United States; On-site; USD 80,000 - 110,000; Full time

Job summary

PPC Flex Company in the United States seeks a Lean Process Engineer to develop and improve manufacturing processes by studying product and methods, collaborating with cross-functional teams to implement sustainable improvements.

You will lead Lean initiatives, apply A3, 6S, Kaizen events, and DOE to reduce waste, control changes, and drive CAPA-driven quality. Bachelor’s in Engineering and 3+ years of manufacturing experience are required.

Qualifications

• Bachelor's degree in Engineering or equivalent.
• 3+ years’ experience in manufacturing, preferably in a food manufacturing industry.
• Strong analytical skills and problem-solving mindset.
• Able to read and understand work instructions and take direction effectively.
• Lean green belt certification required or equivalent.

Responsibilities

• Provide guidance in manufacturing processes in an industrial plant and develop, evaluate, and improve manufacturing methods.
• Identify and apply manufacturing best practices to improve productivity, cost, quality, and responsiveness.
• Lead the implementation of Lean manufacturing principles across the organization and deploy Lean methodologies (A3, 6S, Kaizen).
• Act as a change agent to manage continuous improvement across the facility.
• Facilitate projects to improve quality, reduce costs, improve cycle time, and reduce waste.
• Develop and implement Lean principles to enhance work processes and deliver significant cost savings and improved safety.
• Build a continuous improvement culture and train employees in Lean initiatives such as Kanban, VSM, Takt Time, and Kaizen.
• Develop Value Stream Maps, identify waste, and prioritize actions by ROI.
• Improve MOC processes and provide training to stakeholders (Safety, Quality, Production, Maintenance).
• Collaborate with Maintenance and Production on PM recommendations to optimize quality and uptime.
• Use DOE to identify setup parameters and ensure machine capability limits are understood.
• Document best practice setup parameters and deploy SOPs for each item type and asset.
• Improve workflow, space requirements, and equipment layout.
• Ensure compliance with company procedures and quality standards; participate in quality programs.
• Assist with training less experienced engineers as needed.
• Maintain knowledge through workshops and professional networks.

Skills

Lean manufacturing

Data analysis

Problem-solving

Communication skills

Education

Bachelor's degree in Engineering

Job description

The Lean Process Engineer develops and improves manufacturing processes by studying product and manufacturing methods. He/she will collaborate with cross-functional departments to implement sustainable process improvements. He/She will also investigate and analyze quality problems, recommending solutions and ensuring corrections are made through the CAPA process. Be a champion of continuous improvement throughout the entire manufacturing facility. In the event of absence, these job responsibilities will be covered by other employees in the “Plant Engineer” or “Plant Manager” positions.

Responsibilities and Duties:

• Provide guidance in manufacturing processes in an industrial plant. Develops, evaluates, and improves manufacturing methods, using knowledge of the organization's processes.
• Identifies and applies manufacturing best practices in an industrial plant. Research new manufacturing technology and processing methods to improve the organization's productivity, cost, quality, and responsiveness.
• Leads the implementation of Lean manufacturing principles throughout the organization. Deploy other Lean methodologies such as the A3 Process, 6S, Kaizen events, etc.
• Act as a change agent for leading and managing continuous improvement throughout the manufacturing facility.
• Facilitate key projects that will improve quality, reduce costs, improve cycle time, and provide the optimum benefits to customers and the business through waste reduction.
• Develop and implement continuous improvement (Lean manufacturing) principles to enhance work processes and output which leads to significant cost savings, improved customer service, improved quality, and improved safety for the organization.
• Build a continuous improvement culture and drive change throughout the organization. Train all employees in the basics of lean manufacturing and train production teams in lean manufacturing initiatives such as Kanban, Value Stream Mapping, Takt Time Analysis, and Kaizen.
• Develop Value Stream Maps for all production departments / assets. Identify waste within those processes and propose actions necessary to reduce / eliminate waste. Prioritize by return on investment.
• Enhance the Management Of Change (MOC) process and ensure strict adherence for either process or equipment changes. Provide training to key stakeholders, such as Safety, Quality, Production and/or Maintenance departments.
• Collaborate with Maintenance and Production on Preventative Maintenance (PM) recommendations for optimal product quality and machine uptime. Review existing PM’s for effectiveness.
• Utilize Design Of Experiments (DOE) to identify machine setup parameters that product consistency and throughput, conferring with machine vendors where necessary to understand the machine capability limits.
• Capture best practice machine setup parameters, database and deploy as Standard Operating Procedure (SOP) for each item type + asset.
• Improve manufacturing efficiency by analyzing and planning work flow, space requirements, and equipment layout.
• Ensure that all responsibilities and functions performed are in accordance with company procedures and meet quality standards in place. Participate in quality programs and stay updated on changes and standards within the systems.
• Assist with training less experienced engineers as needed.
• Maintains professional and technical knowledge by attending educational workshops; reviewing professional publications; establishing personal networks; participating in professional societies.
• Contributes to team effort by accomplishing related results as needed.
• Perform other duties which may be assigned as part of the essential functions of the position.
• Be Safe! Encourage all employees to engage in safe working behaviors.

Skills and Qualifications:

• Bachelor’s degree in Engineering, or equivalent experience.
• 3+ years’ experience in manufacturing, preferably in a food manufacturing industry.
• Strong analytical skills, excellent problem-solving mindset.
• Able to read and understand work instructions and accept verbal direction to successfully complete procedures and assigned tasks.
• A minimum certification of Lean green belt.
• Good verbal and written communication skills required, and proven experience with effective teams and continuous improvement methods strongly preferred.