Lean Manufacturing Engineer

Hapco Pole Products; Abingdon (VA); On-site; USD 85,000 - 120,000; Full time

Job summary

Hapco Pole Products in Abingdon, VA is seeking a Lean Manufacturing Engineer to drive continuous improvement across its manufacturing operations. You will identify waste, boost productivity, and strengthen quality, safety, and profitability in support of strategic objectives.

You will lead Lean program development (Value Stream Mapping, 5S, TPM, and standardized work), coach teams, monitor metrics, and collaborate with Operations and Engineering to implement sustainable improvements.

Qualifications

• Bachelor's degree in Mechanical, Industrial, or Manufacturing Engineering.
• 3–5 years Lean Manufacturing experience in a manufacturing environment.
• Experience implementing Lean methodologies and leading operational initiatives.
• Experience with project management and production cost analysis.
• Knowledge of Six Sigma and continuous improvement methodologies.
• Strong analytical, organizational, and communication skills.
• Ability to prioritize multiple projects in a fast-paced environment.

Responsibilities

• Develop and maintain Lean manufacturing roadmap aligned with business objectives.
• Partner with management to set Lean goals, metrics, and initiatives.
• Lead continuous improvement efforts to reduce waste and improve throughput.
• Coach teams and drive engagement in Lean initiatives across facilities.
• Lead TPM, 5S, standard work, and other Lean methods in programs.
• Analyze processes, track performance, and implement corrective actions.
• Collaborate with Operations, Engineering, and Quality to meet targets.

Skills

Lean Manufacturing

Continuous Improvement

Six Sigma

Project Management

Data Analysis

Communication

Organizational Skills

Education

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Industrial Engineering

Bachelor's degree in Manufacturing Engineering

Job description

The Lean Manufacturing Engineer is responsible for driving continuous improvement and implementing Lean Manufacturing principles throughout the organization. This role supports operational excellence by identifying and eliminating waste, improving efficiency, enhancing quality, and fostering a culture of continuous improvement across manufacturing operations.

Reporting directly to the Manufacturing Engineering Manager, this position develops, implements, and sustains Lean initiatives that improve productivity, quality, safety, and profitability while supporting strategic business objectives.

Key Responsibilities

Lean Leadership & Continuous Improvement

• Develop and maintain the organization's Lean Manufacturing roadmap in alignment with business objectives.
• Partner with management to establish Lean goals, metrics, and improvement initiatives.
• Monitor and report Lean implementation progress and results.
• Lead continuous improvement efforts focused on eliminating waste and increasing operational effectiveness.
• Promote employee engagement and participation in Lean initiatives.
• Coordinate best practice sharing across departments and facilities as appropriate.

Lean Program Development & Implementation

• Develop and implement Lean manufacturing programs, policies, procedures, and work instructions.
• Establish systems and support structures that facilitate information flow, process reviews, and Lean tool deployment.
• Lead implementation of Lean methodologies including Value Stream Mapping, Kaizen, 5S, Total Productive Maintenance (TPM), Set-Up Reduction, Standardized Work, and One-Piece Flow.
• Manage continuous improvement projects from concept through implementation and sustainment.
• Ensure Lean initiatives support safety, quality, delivery, and cost objectives.
• Develop master plans for major Lean transformation efforts.

Training & Employee Development

• Train and coach employees, supervisors, and leadership teams in Lean Manufacturing principles and continuous improvement methodologies.
• Facilitate workshops, events, and improvement activities throughout the facility.
• Provide hands‑on coaching and mentoring to support successful Lean implementation.
• Foster a culture of accountability, problem-solving, and operational excellence.

Operational Support & Process Optimization

• Conduct improvement events on the manufacturing floor and ensure successful implementation of corrective actions.
• Analyze manufacturing processes and identify opportunities to increase efficiency, reduce waste, and improve product flow.
• Work closely with Manufacturing and Engineering teams to implement process and design improvements.
• Support development and maintenance of advanced Lean systems and production methods.
• Track performance metrics and recommend adjustments to achieve targeted results.

Cross-Functional Collaboration

• Collaborate with Operations, Engineering, Quality, and other departments to achieve continuous improvement objectives.
• Support integration of Lean Manufacturing initiatives with ISO 9001 and other quality management systems.
• Build positive working relationships with internal and external stakeholders.
• Effectively communicate project status, progress, challenges, and opportunities to leadership.

Travel Requirements

• Travel is required up to 30% and may include visits to other company facilities, projects, training events and cross-functional collaborations.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or a related technical discipline.
• Minimum three (3) to five (5) years of Lean Manufacturing experience in a manufacturing environment.
• Demonstrated experience implementing Lean methodologies and leading operational improvement initiatives.
• Experience with project management and production cost analysis.
• Knowledge of Six Sigma and continuous improvement methodologies.
• Strong analytical, organizational, and communication skills.
• Ability to prioritize multiple projects and work effectively in a fast-paced environment.

Reasoning Ability

• Ability to apply common-sense understanding when carrying out instructions provided in written, oral, or diagram form.
• Ability to create, read, and accurately interpret documents.
• Strong problem-solving skills with the ability to manage situations involving multiple variables and changing priorities.
• Ability to analyze data and translate findings into actionable process improvements.

Physical Demands

• Perform movements such as climbing, balancing, stooping, kneeling, crouching, or crawling.
• Must be able to occasionally lift and/or move up to 20 pounds.
• Requires close vision, peripheral vision, and the ability to adjust focus.
• Ability to stand and walk for extended periods while supporting manufacturing operations.
• Frequent use of hands to finger, handle, and feel.

Work Environment

• The position is primarily office-based with regular involvement in the manufacturing plant. Required personal protective equipment (PPE) and all plant safety procedures must be followed while in production areas.