Senior Process Engineer

DSJ Global; Phillipsburg (KS); On-site; USD 100,000 - 140,000; Full time

Job summary

DSJ Global is seeking an AI Six Sigma Lead for a Senior Process Engineer role in Phillipsburg, Kansas. You will drive operational excellence by integrating AI, advanced analytics, and Lean Six Sigma methodologies across manufacturing, quality and operations teams to identify optimization opportunities and deploy AI-driven solutions.

Lead cross-functional improvement projects, develop KPI dashboards, and mentor staff while staying current with Industry 4.0 and smart manufacturing trends.

Qualifications

• Bachelor's degree in Engineering, Data Science, Mathematics, Statistics, Industrial Technology, or another STEM-related field.
• 3+ years of experience in Process Engineering, Continuous Improvement Engineering, Quality Engineering, Manufacturing Engineering, or a related manufacturing role.
• Demonstrated experience leading Continuous Improvement projects with measurable results.
• Working knowledge of Lean Manufacturing, Six Sigma, DMAIC, Root Cause Analysis, and statistical process control.
• Familiarity with AI, machine learning, data analytics, or predictive modeling concepts.
• Strong analytical, project management, and communication skills.

Responsibilities

• Lead Lean Six Sigma and Continuous Improvement initiatives across manufacturing operations.
• Identify opportunities to utilize AI, machine learning, predictive analytics, and data-driven tools to improve operational performance.
• Analyze production, quality, and operational data to identify trends, waste, bottlenecks, and improvement opportunities.
• Develop and implement AI-enabled solutions that improve process capability, yield, quality, cycle time, and equipment effectiveness.
• Facilitate Kaizen events, value stream mapping exercises, root cause analyses, and problem-solving workshops.
• Partner with manufacturing, quality, engineering, and operations leadership to prioritize and execute improvement projects.
• Develop KPI dashboards and performance metrics to monitor project outcomes and operational performance.
• Utilize DMAIC, statistical analysis, process mapping, and Lean methodologies to drive measurable business results.
• Train and mentor employees on Continuous Improvement principles and data-driven decision-making.
• Stay current on advancements in AI, machine learning, and smart manufacturing technologies and identify opportunities for implementation.

Skills

Lean Six Sigma

DMAIC

Root cause analysis

Statistical analysis

Analytical skills

Education

Bachelor's degree in Engineering or STEM field

Tools

Power BI

Tableau

Python

SQL

Minitab

Job description

Senior Process Engineer (PR/603169) Phillipsburg, Kansas

Salary: USD100000 - USD140000 per annum

About the Role

Our client is seeking an AI Six Sigma Lead to drive operational excellence through the integration of Artificial Intelligence (AI), advanced analytics, and Continuous Improvement methodologies. This individual will partner closely with manufacturing, engineering, quality, and operations teams to identify opportunities for optimization, deploy AI-driven solutions, and lead Lean Six Sigma projects that improve productivity, quality, cost, and throughput.

This is a highly visible role focused on leveraging emerging technologies to transform manufacturing processes while championing a culture of continuous improvement across the organization.

Key Responsibilities

• Lead and execute Lean Six Sigma and Continuous Improvement initiatives across manufacturing operations.
• Identify opportunities to utilize AI, machine learning, predictive analytics, and data-driven tools to improve operational performance.
• Analyze production, quality, and operational data to identify trends, waste, bottlenecks, and improvement opportunities.
• Develop and implement AI-enabled solutions that improve process capability, yield, quality, cycle time, and equipment effectiveness.
• Facilitate Kaizen events, value stream mapping exercises, root cause analyses, and problem-solving workshops.
• Partner with manufacturing, quality, engineering, and operations leadership to prioritize and execute improvement projects.
• Develop KPI dashboards and performance metrics to monitor project outcomes and operational performance.
• Utilize DMAIC, statistical analysis, process mapping, and Lean methodologies to drive measurable business results.
• Train and mentor employees on Continuous Improvement principles and data-driven decision-making.
• Stay current on advancements in AI, machine learning, and smart manufacturing technologies and identify opportunities for implementation.

Qualifications

Required

• Bachelor's degree in Engineering, Data Science, Mathematics, Statistics, Industrial Technology, or another STEM-related field.
• 3+ years of experience in Process Engineering, Continuous Improvement Engineering, Quality Engineering, Manufacturing Engineering, or a related manufacturing role.
• Demonstrated experience leading Continuous Improvement projects with measurable results.
• Working knowledge of Lean Manufacturing, Six Sigma, DMAIC, Root Cause Analysis, and statistical process control.
• Familiarity with AI, machine learning, data analytics, or predictive modeling concepts.
• Strong analytical, project management, and communication skills.

Preferred

• Experience applying AI or advanced analytics to manufacturing, quality, or operational processes.
• Proficiency with analytical tools such as Power BI, Tableau, Python, SQL, Minitab, or similar platforms.
• Knowledge of Industry 4.0, Smart Manufacturing, automation, and digital transformation initiatives.
• Experience driving cross-functional improvement projects within a manufacturing environment.