Lean Manufacturing Engineer: Process Optimization & Kaizen

Southern Company; Northern (KY); Hybrid; USD 90,000 - 120,000; Full time

Benefits offered by this job

Medical, dental, vision coverage

Competitive pay and 401(k)

Job summary

PowerSecure, a Southern Company subsidiary, seeks a Manufacturing Engineer II to drive lean improvements, standard work, and efficient MoMs. You will collaborate across departments to optimize layouts, BOM support, and material flow, while maintaining CAD layouts and leading Kaizen events.

You will evaluate processes, develop SOPs, and support leadership with actionable manufacturing improvements, fostering a lean culture and hands-on shop floor leadership.

Qualifications

• Bachelor’s degree in Engineering (Industrial or Mechanical preferred).
• 4+ years of experience in a manufacturing environment.
• Experience with Lean/Continuous Improvement; Green Belt certification preferred.
• Experience in assembly of generator sets, switchgear, and/or metal fabrication equipment preferred.
• Strong problem-solving skills using engineering principles and techniques.
• Hands-on production shop floor experience.
• Effective communication skills, especially when resolving assembly issues with production teams.
• Proficient in Microsoft Office, CAD systems, data analysis, and database tools.
• Experience with facility layout design using AutoCAD.
• Basic understanding of ERP systems (IFS preferred).
• Ability to read and interpret drawings, 3D models, specification sheets, and shop orders.
• Solid understanding of flow diagrams, Value Stream Mapping (VSM), PFMEAs, and layout design.
• Results-driven, with the ability to build strong relationships and manage multiple projects simultaneously.
• Self-starter with a strong sense of urgency and ownership.
• Understanding of integrating automation and AI into manufacturing processes.
• Basic knowledge of G-code.

Responsibilities

• Collaborate cross-functionally across departments to support operational goals.
• Lead shop floor 5S initiatives.
• Develop and improve processes, including Standard Work, SOPs, work instructions, and flowcharts.
• Analyze data to identify waste and process bottlenecks.
• Lead Lean activities such as Kaizen events, Value Stream Mapping (VSM), and process mapping.
• Design and optimize work center layouts to improve use of space, materials, personnel, and equipment.
• Support BOM setup, including product structure and routings.
• Maintain and update facility layouts in CAD to reflect improvements, relocations, and growth.
• Conduct time studies and observations as needed.
• Perform capacity analysis and drive material flow improvements (e.g., pacing charts, methods of manufacturing).
• Partner with Material Planning to enhance material flow (e.g., Kanban, point-of-use storage).
• Collaborate with METs on product improvements, including DFMA, machine capabilities, tooling aids, and poka-yoke solutions.
• Provide hands-on support to the shop floor on manufacturing processes.
• Develop solutions and recommendations for leadership to address manufacturing challenges.
• Promote and reinforce a Lean manufacturing culture.
• Design and develop tools and equipment to improve process efficiency.
• Nest parts for fabrication equipment such as lasers, water jets, and copper punch machines.

Job description

PowerSecure, a Southern Company subsidiary, seeks a Manufacturing Engineer II to drive lean improvements, standard work, and efficient MoMs. You will collaborate across departments to optimize layouts, BOM support, and material flow, while maintaining CAD layouts and leading Kaizen events.

You will evaluate processes, develop SOPs, and support leadership with actionable manufacturing improvements, fostering a lean culture and hands-on shop floor leadership.