Lean Engineer

Vestas; Windsor (CO); On-site; USD 75,000 - 100,000; Full time

Benefits offered by this job

Benefits coverage within your first 30

Training Program

Paid Time Off (PTO)

401(k) Plan

Annual bonus

Job summary

Vestas Windsor Blades Factory is seeking a Team Leader - Lean Engineer to drive factory improvements using Lean tools, VSM, takt, kanban, and 5S. The role includes Kaizen events, PFMEA support, and NPI ramp-up activities.

Collaboration with HQ and cross-functional teams is essential to achieve stable serial production. Ideal candidates have a 3–5+ year background in Lean/manufacturing engineering, strong data analysis skills, and Green Belt or higher.

Qualifications

• Bachelor’s degree in Mechanical/Industrial Engineering or related field.
• 3–5+ years in Lean, continuous improvement, or manufacturing engineering.
• Strong knowledge of Lean tools: VSM, takt, kanban, 5S, kaizen, SMED, standard work.
• Lean Six Sigma Green Belt or higher preferred; use of Six Sigma tools to reduce variation.
• Experience with PFMEA, Control Plans, and structured problem solving.
• Proficiency in data analysis, time studies, and capacity modeling.
• Strong communication and cross-functional collaboration skills.

Responsibilities

• Drive factory improvements with Lean assessments and actions.
• Maintain Daily Management System, leader standard work, and KPI boards.
• Engineer flow and stability with VSM, takt time, line balancing, and kanban.
• Facilitate kaizen events, 5S activities, and problem-solving workshops.
• Support PFMEA development and alignment with controls and testing.
• Support NPI and ramp-up for stable serial production.
• Collaborate with HQ and cross-functional teams on NPI/TT deliverables.
• Share best practices across factories for global standardization.
• Conduct time studies, capacity analyses, and labor/equipment reviews.
• Implement poka-yoke, confirmations, layered audits, and audits.
• Ensure compliance with QBD, ECM, ToCI, and controlled docs.
• Participate in improvement projects and layout optimization.
• Perform other duties as assigned.

Skills

Lean manufacturing

Value Stream Mapping

Takt time

Kanban systems

5S

Kaizen

SMED

Data analysis

Time studies

Microsoft Office

Education

Bachelors in Mechanical Engineering

Bachelors in Manufacturing Engineering

Tools

PFMEA

Control Plans

CAD

AutoCAD

Excel

Job description

Production

Team Leader | Full-Time | Production At Vestas, we are driven by a shared purpose: to power the world with sustainable energy. As the global leader in wind energy, we design, manufacture, install, and service wind turbines that help create a cleaner and more sustainable future.

Join our Windsor Blades Factory, where innovation, quality, and teamwork come together to produce some of the world\'s most advanced wind turbine blades.

What Does a Lean Engineer Do?

• Drive factory improvements by conducting Lean assessments and implementing targeted improvement actions.
• Maintain adherence to the Daily Management System, including leader standard work, visual KPI boards, and escalation rules.
• Engineer flow and process stability by Value Stream Mapping (VSM), setting takt time, performing line balancing, and designing kanban systems. Analyze processes to identify waste, variation, and bottlenecks; implement solutions that improve safety, quality, delivery, cost, and people performance.
• Facilitate kaizen events, 5S activities, and structured problem-solving workshops.
• Support PFMEA (Process Failure Mode and Effects Analysis) development and alignment with Control Plans, PWIs, testing, tooling RFPs, worker balance, and process capability.
• Support NPI and ramp-up activities to achieve stable serial production.
• Collaborate with HQ and cross-functional teams to support NPI/TT (Technology Transfer) deliverables and readiness.
• Foster sharing of best practices across factories to strengthen global standardization.
• Conduct time studies, capacity analysis, and labor/equipment utilization reviews.
• Implement poka-yoke, confirmations, layered audits, and other first-time-right quality controls.
• Ensure compliance with QBD (Quality Before Delivery), ECM (Engineering Change Management), ToCI (Transfer of Component Information), and revision-controlled documentation.
• Participate in improvement projects, capacity expansions, and layout optimization.
• Perform other duties as assigned.

Essential Functions

• Apply Lean tools (VSM, 5-Why, 8D, SMED, standard work) to stabilize and improve production processes.
• Communicate process changes and improvement outcomes clearly to operators, technicians, and leadership.
• Maintain accurate documentation, KPIs, and Daily Management System data.
• Work on the factory floor as needed to support improvement activities and coaching.

What You Will Bring:

• Bachelor’s degree in Mechanical, Manufacturing/Industrial Engineering, Operations, or related field; equivalent experience considered.
• 3–5+ years of experience in Lean, continuous improvement, or manufacturing engineering.
• Strong knowledge of Lean tools (VSM, takt, kanban, 5S, kaizen, SMED, standard work).
• Lean Six Sigma certification (Green Belt or higher) strongly preferred; demonstrated application of Six Sigma tools to reduce variation and improve process capability.
• Experience with PFMEA, Control Plans, and structured problem solving.
• Proficiency in data analysis, time studies, and capacity modeling.
• Strong communication, facilitation, and cross-functional collaboration skills.
• Ability to influence without authority and drive change in a production environment.
• Advanced Microsoft Office skills; CAD experience preferred.

What You Will Receive:

We offer an attractive salary and one of the most comprehensive benefits plans in the industry, including:

• Benefits coverage within your first month
• State-of-the-art Training Program
• Paid Time Off (PTO)
• Excellent 401(k) Plan
• Annual bonus

Job Type: Full-time

Salary range: $75,000 - $100,000 a year.

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