Operational Excellence Engineer

Delta Star Inc.; Lynchburg (VA); Hybrid; USD 108,000 - 174,000; Full time

Job summary

Delta Star Inc. is seeking an Operational Excellence Engineer to lead performance improvement across manufacturing processes and value streams.

This role blends lean principles with cross-functional leadership and deep technical expertise to drive safety, quality, delivery, cost, and productivity. The position is hybrid, requiring onsite presence one week per month at Lynchburg, VA, with opportunity to influence across multiple sites.

Qualifications

• Bachelor’s degree in Industrial, Mechanical, Electrical, or Manufacturing Engineering.
• 5–10 years in manufacturing or operational excellence roles.
• Experience leading cross-functional projects without direct authority.
• Lean, Six Sigma, Value Stream Mapping, Kaizen experience; transformer/heavy manufacturing preferred.

Responsibilities

• Lead continuous improvement and transformation initiatives across the organization.
• Standardize best practices and eliminate waste across sites.
• Develop improvement roadmaps aligned with business priorities.
• Benchmark and implement scalable manufacturing innovations.
• Coach and mentor cross-functional teams on Lean tools.

Skills

Lean Manufacturing

Six Sigma

5S

Continuous improvement

Manufacturing processes

KPIs / metrics

Financial acumen

Change management

Cross-functional leadership

Project management

CAD

ERP systems (Dynamics 365)

MS Office / Project

English fluency

Education

Bachelor’s degree in Industrial, Mechanical, Electrical, or Manufacturing Engineering

Tools

CAD

ERP (Dynamics 365)

MS Office & Project

Job description

Build something that matters.

At Delta Star the work we do has a real impact. Every transformer we build helps deliver reliable electricity to homes, businesses, and communities across North America.

As we continue to grow, we are looking for people who want more than just a job. We are looking for individuals who want to learn, contribute, solve challenges, and build a meaningful career alongside a team that is committed to delivering power at all times.

This is a hybrid position that requires onsite presence for one week per month at one of the following plant locations: San Carlos, CA; Lynchburg, VA; or Saint-Jean-sur-Richelieu, QC.

Summary

Delta Star Inc. is seeking a strategic, results-driven Operational Excellence Engineer to lead performance improvement and transformation across manufacturing processes and value streams. This role is a key driver of operational success-combining deep technical expertise, lean principles, and cross-functional leadership to improve safety, quality, delivery, cost, and productivity. If you thrive in complex environments and enjoy driving measurable business impact, we want to hear from you!

What You’ll Do

As an Operational Excellence Engineer, you will serve as a subject matter expert and process owner, leading continuous improvement and transformation initiatives across the organization. You’ll partner with Operations, Engineering, Quality, and other teams to standardize best practices, eliminate waste, and implement scalable improvements. You’ll also help shape the future of manufacturing by evaluating new technologies and advancing operational capabilities.

A Day in the Life

Your day may include facilitating a Kaizen event, analyzing value stream performance, or collaborating with plant leadership to improve workflow and reduce inefficiencies. You’ll lead cross-functional projects, track key performance metrics, and develop improvement roadmaps that align with broader business objectives. Whether you’re standardizing processes across sites or mentoring teams on Lean tools, your work directly drives measurable improvements in operational performance.

Specific Duties

• Own and manage performance of assigned manufacturing processes and value streams.
• Develop and maintain value stream maps to identify waste and improvement opportunities.
• Lead Kaizen events, continuous improvement initiatives, and problem-solving activities.
• Deploy Lean tools such as 5S, standard work, and visual management systems.
• Define, update, and standardize SOPs, work instructions, and process documentation.
• Develop and execute improvement roadmaps aligned with business priorities.
• Track and communicate operational KPIs and financial impact of improvements.
• Collaborate with Engineering and Quality to ensure manufacturability and compliance.
• Support facility layout optimization and workflow improvements.
• Drive standardization of best practices across multiple sites.
• Evaluate emerging technologies and manufacturing innovations.
• Conduct site visits to assess performance and support implementation efforts.
• Participate in benchmarking, supplier visits, and industry events to identify best practices.

What We’re Looking For

We’re looking for a high-impact change leader with strong operational expertise and the ability to drive transformation through structured problem-solving and cross-functional influence.

Position Requirements

• Bachelor’s degree in Industrial, Mechanical, Electrical, or Manufacturing Engineering.
• 5-10 years of experience in manufacturing, engineering, or operational excellence roles.
• Proven experience leading cross-functional projects and influencing stakeholders without direct authority.
• Experience with Lean, Six Sigma, Value Stream Mapping, Kaizen, or related methodologies.
• Experience driving organizational change and process standardization.
• Experience in transformer or heavy manufacturing environments preferred.
• Multisite experience preferred.
• Fluency in English required; French or Spanish a plus.

Skills & Competencies

• Advanced knowledge of Lean Manufacturing, Six Sigma, 5S, and continuous improvement tools.
• Strong understanding of manufacturing processes, workflow optimization, and performance metrics.
• Ability to analyze SQDC metrics and develop data-driven solutions.
• Strong financial acumen with ability to quantify business impact.
• Exceptional change management, coaching, and stakeholder engagement skills.
• Ability to lead and influence cross-functional teams without direct authority.
• Strong project management and execution capability.
• Experience developing standard work and training materials.
• Working knowledge of CAD, manufacturing drawings, and process design.
• Proficiency with Microsoft Office, Project, and ERP systems (e.g., Dynamics 365).
• Ability to balance strategic thinking with hands-on execution.

Travel Requirements

• Approximately 25-50% travel, including domestic and international
• Regular travel across U.S. and Canadian facilities
• Remote-capable with one week per month onsite at a Delta Star facility

Please note that the salary range displayed applies only to positions located in California and Virginia. Compensation for positions based in Canada is determined according to local market conditions and may differ from the salary range shown.

The salary range for this position is $107,500 - $134,400 in the State of Virginia

The salary range for this position is $139,300 - $174,200 in the State of California

Why Our Employees Join, Grow, and Stay

At Delta Star, you will find more than a job. You will join a team that values people, supports growth, and trusts you to make an impact. Whether you're on the shop floor, in the field, or in the office, you will work alongside talented people to solve meaningful challenges, power communities, and build a rewarding career. With opportunities to learn, advance, and contribute, plus a culture built on respect, teamwork, and work-life balance, Delta Star is a place where you can thrive for the long term

Benefits That Support You

We believe that a rewarding career starts with feeling supported both at work and at home. That's why we offer a competitive total rewards package designed to support your health, financial well-being, professional growth, and work-life balance. Eligible employees have access to medical, dental, and vision coverage, retirement savings programs, paid time off, life and disability protection, wellness resources, employee assistance programs, and additional voluntary benefits that help you and your family thrive.

Pay Transparency

We are committed to fair and transparent pay practices. Compensation for this position will be determined within the posted salary range based on factors such as candidate qualifications, relevant experience, internal equity, market competitiveness, skills, and certifications. For union-represented roles, pay is established by the applicable collective bargaining agreement.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities, and activities may change at any time with or without notice.

AAP/EEO Statement

Delta Star is an EEO/Affirmative Action Employer and does not discriminate on the basis of age, race, color, religion, gender, sexual orientation, gender identity, gender expression, national origin, protected veteran status, disability or any other legally protected status.