Senior Lean Process Improvement Engineer

Socket.dev; Washington (NC); On-site; USD 90,000 - 130,000; Full time

Job summary

AAF International seeks a Continuous Improvement Engineer to lead lean transformations, stabilize processes, and drive data‑driven improvements on the shop floor. This role focuses on achieving sustainable gains through standard work, SPC, and visual management.

You will coach teams, apply structured problem solving (DMAIC/PDCA/Shainin Red X), and collaborate across Operations, Engineering, Quality, Maintenance, and Supply Chain to deliver measurable ROI.

Qualifications

• 4–6 years in a manufacturing or industrial environment.
• Experience owning manufacturing processes and sustaining process control.
• Working knowledge of Lean manufacturing principles and tools.
• Understanding of industrial automation and its application to manufacturing improvement.
• Experience developing or supporting ROI and cost justification for improvement or capital projects.
• Effective communication skills and comfort working cross‑functionally.
• Ability to support cultural change while balancing data‑driven analysis and practical problem solving.

Responsibilities

• Serve as a process subject matter expert for assigned manufacturing processes, understanding process flow, capability, constraints, and risks.
• Lead efforts to bring processes into statistical control and sustain gains using standard work, control plans, SPC, and visual management.
• Recommend and implement improvements to production processes, methods, and controls.
• Apply analytical and creative thinking to solve manufacturing problems and improve performance.
• Lead, support, and facilitate the ongoing shift toward a Lean culture across the organization.
• Act as a coach and change agent by helping teams understand why Lean practices are used, not just how.
• Encourage employee engagement and ownership of continuous improvement at all levels.
• Partner with leaders and teams to reinforce Lean behaviors, standard work, and continuous improvement routines.
• Help embed Lean thinking into daily management systems and decision-making.
• Utilize at least one structured problem-solving methodology, such as DMAIC, PDCA, or Shainin Red X.
• Define problems clearly, identify and validate root causes, implement effective solutions, and establish controls to sustain results.
• Support team-based problem-solving activities and knowledge sharing.
• Facilitate and participate in cross-functional Kaizen events, recognizing the value of collaboration across Operations, Engineering, Quality, Maintenance, and Supply Chain.
• Support continuous improvement through hands‑on involvement in shop‑floor activities.
• Plan, design, implement, and improve manufacturing systems that support performance, reliability, maintainability, schedule adherence, and cost control.

Skills

Statistical control

Standard work

SPC

Visual management

DMAIC

PDCA

Shainin Red X

Root cause analysis

Cross-functional collaboration

Education

Bachelor's degree in Mechanical or Industrial Engineering

Tools

Kaizen

5S

Kanban/Pull systems

Time studies / MTM

Automation awareness

Job description

AAF International seeks a Continuous Improvement Engineer to lead lean transformations, stabilize processes, and drive data‑driven improvements on the shop floor. This role focuses on achieving sustainable gains through standard work, SPC, and visual management.

You will coach teams, apply structured problem solving (DMAIC/PDCA/Shainin Red X), and collaborate across Operations, Engineering, Quality, Maintenance, and Supply Chain to deliver measurable ROI.