Continuous Improvement Process Engineer

RESPONSIBILITIES AND PHILOSOPHY

1. Operator Development and Empowerment
   • Improve process yield, scrap, rework and manufacturing efficiency by analyzing the process and planning workflow, space requirements, and equipment layout. Coordinate input that may cross multiple teams or areas; make recommendations and implement changes.
   • Responsible for maximizing the following: (1) Cost Effectiveness; (2) Scrap Reduction; (3)Overall Equipment Effectiveness (OEE); (4) Single Minute Exchange of Die (SMED); (5) Mill Uptime and (6)Reliability towards manufacturing flow, processes and equipment.
   • Facilitates time studies, capacity analysis, space optimization, process lay‑outs to support the vision of flow and optimize cost through driving process efficiencies and value stream improvements with the value stream.
   • Assist in technical input to perform corrective actions using 8-D format, fault trees, cause & effect diagrams, 5 Whys, A3, Design of Experiment and other tools; and to communicate data internally and externally.
   • Participates in the AS9100/ISO9001/IATF quality management system requirements Refine and enhance processes by applying continuous improvement and key Lean manufacturing/production principles and techniques to areas of production. Recommend product changes/improvements.
   • Identify and implement solutions for issues relating to safety, quality, productivity, and cost reductions.
   • Develop innovative solutions to complex manufacturing production problems through identification and implementation of advanced manufacturing processes including conducting process analysis, applying knowledge of product design and materials, and soliciting observations from the operators/production technicians.
   • Prepare documentation for new manufacturing processes.
   • Prepare reports summarizing analyzed process information and trends.
   • Assure product and process quality by testing process capabilities and establishing standards to confirm and validate manufacturing process requirements.
   • Determine root cause of failures using statistical methods (e.g., design of experiment, SPC) that may result in recommended changes in design, tolerances, or processing methods.
2. Active Gemba and Process Robustness
   • Support the VSM, lead hands, operators and transactional support groups in recovery and preventive actions for rework, setup, and changeovers.
   • Application of Lean Six Sigma Methodologies (DMAIC, DMADV)
   • Use the necessary lean tools, supplies and guidance to improve effectiveness.
   • Reinforce (1)5S; (2)Idea Management; (3)Time Studies, (4)Space optimization, (4)Kaizen, (5)Kanban, (6)Hoshin Kanri, (7)Poka‑Yoke; (8) SIPOC; (9)SMED; (10)Obeya; (11)Leader Standard Work; (12)Gemba and (13)Value Stream Mapping.
   • Collaborate with management to prioritize improvement efforts based on data, impact, and feasibility.
3. Behavioral and Process Analysis
   • Use pain point logs, cause-and-effect diagrams, 5 Whys, and other Lean Six Sigma tools to identify root causes at the real place (Gemba).
   • Application of Lean Six Sigma Methodologies (DMAIC, DMADV)
   • Facilitation of (1)Project Drilldown Analysis; (2)Project Charters; (3)8D; (4)A3; (5)Kaizen
4. Analytical and Technical Responsibilities
   • Collaborate with Management, Quality Assurance, Group Engineering, and other departments to execute and sustain improvements.
   • Must be proficient in applications used for documentation and data analysis including but not limited to: Excel, Word, PowerPoint, Visio, Power BI, SQL, Tableau, Python, AutoCAD, Solid Works, Apollo
   • Knowledge of JDE systems
5. Benchmarking & Standardization Framework
   • Internal Benchmark: Observe and assist operators to identify real issues, wastes, constraints and root causes.
   • Functional Benchmark: Research operational excellence relative to Process Engineering improvements across similar or divergent industries especially Tubing, Aerospace and Data Center.
6. Collaboration and Cross-Departmental Integration
   • Partner with VSM, QA, CI, Maintenance to ensure equipment robustness and reduce operator struggles.
   • Collaborate with Management and HR for alignment, morale, and training.
   • Support business expansion by improving employee engagement, process capability, compliance, and reducing Cost of Poor Quality (COPQ).
7. Apply Frameworks for Lean Quick Wins
   • Empower operators to stop the process when issues occur. Build quality at th