Lean Process Engineer: Drive Continuous Improvement

PPC-Flex; Buffalo Grove (IL); On-site; USD 74,000 - 92,000; Full time

Job summary

PPC-Flex in Buffalo Grove, IL is seeking a Lean Process Engineer to develop and improve manufacturing processes and drive continuous improvement across the plant. You will collaborate with cross-functional teams to implement sustainable changes and reduce costs.

The ideal candidate holds a Bachelor's in Engineering, 5+ years of manufacturing experience (packaging preferred), and Lean Six Sigma Green Belt certification. Strong analytical and communication skills are essential for success.

Qualifications

• 5+ years of experience in manufacturing, preferably in the packaging industry.
• Green Belt Certification ("e.g., Lean Six Sigma Green Belt") OR process engineering background required.
• Strong analytical skills, excellent problem-solving mindset.
• A minimum certification of Lean green belt; black belt preferred.
• Good verbal and written communication skills required, and proven experience with effective teams and continuous improvement methods strongly preferred.

Responsibilities

• 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

Lean Six Sigma Green Belt

Education

Bachelor’s degree in Engineering

Job description

PPC-Flex in Buffalo Grove, IL is seeking a Lean Process Engineer to develop and improve manufacturing processes and drive continuous improvement across the plant. You will collaborate with cross-functional teams to implement sustainable changes and reduce costs.

The ideal candidate holds a Bachelor's in Engineering, 5+ years of manufacturing experience (packaging preferred), and Lean Six Sigma Green Belt certification. Strong analytical and communication skills are essential for success.