Production Improvement Specialist

Position Summary

The Production Improvement Expert is responsible for analyzing, optimizing, and continuously improving production processes to increase efficiency, quality, safety, and cost-effectiveness. This role works closely with production, engineering, quality, maintenance, and supply chain teams to identify opportunities for operational excellence and drive sustainable improvements.

The role focuses on the practical application and improvement of welding, manual machining, CNC machining, setup, tooling, workholding, fixturing, and manufacturing methods. The Production Improvement Specialist helps translate engineering intent and process design into reliable, executable, and repeatable production methods that improve first-time quality, reduce rework and scrap, improve flow, and strengthen process discipline.

Principal Activities

• Providing hands-on technical support for chronic production problems involving welding, manual machining, CNC machining, setup, tooling, workholding, fixturing, and process execution.
• Partnering with the Industrial Engineer and Manufacturing / Methods Engineer to develop, test, validate, and sustain improved manufacturing methods.
• Analyze production processes, workflows, and performance metrics to identify improvement opportunities.
• Lead continuous improvement projects using methodologies such as Lean Manufacturing, Six Sigma, Kaizen, and Total Productive Maintenance (TPM).
• Develop and implement strategies to improve productivity, quality, throughput, and equipment effectiveness.
• Conduct root cause analysis for production issues and implement corrective and preventive actions.
• Monitor key performance indicators (KPIs) including yield, scrap rates, downtime, and cycle times.
• Collaborate with cross-functional teams to implement process improvements and standard operating procedures.
• Support automation and digital transformation projects where applicable.
• Train and coach employees on continuous improvement tools and best practices.
• Ensure compliance with safety, environmental, and quality standards.
• Prepare reports and presentations on improvement initiatives, results, and cost savings.
• Strong project management and problem-solving skills.
• Excellent communication and stakeholder management abilities.

TECHNICAL FOCUS AREAS

Welding Process Improvement

• Support improvement of welding processes, techniques, tooling, fixtures, sequencing, and work aids.
• Provide practical welding expertise during root cause analysis, process development, and improvement activities.
• Support development and improvement of weld methods that increase quality, repeatability, and efficiency.
• Partner with Materials Engineering and Quality on welding procedure development, welder performance considerations, audits, and compliance-related improvement needs.
• Provide input on welding equipment, consumables, workholding, process controls, and advanced welding technologies where applicable.
• Support technical troubleshooting for difficult welds, nonferrous materials, hardfacing/cladding, distortion, accessibility, fit-up, and repeatability challenges.

Manual Machining Process Improvement

• Support improvement of manual machining methods, setup practices, workholding, tooling, inspection points, and operator work aids.
• Provide practical insight into machine behavior, cutting conditions, tool wear, setup variation, part movement, distortion, and sequence-related issues.
• Help identify opportunities to improve repeatability, reduce rework, improve safety, and simplify execution for manual machining operations.

CNC Machining Process Improvement

• Support improvement of CNC machining processes through practical evaluation of setup, tooling, fixturing, machine behavior, program execution, operator interaction, and process stability.
• Partner with Manufacturing / Methods Engineering, CNC programming, and Production to troubleshoot recurring CNC machining issues.
• Provide input on manufacturability, setup reduction, tool selection, workholding, inspection integration, and cell layout for complex machined components.
• Support process improvement efforts for complex stems, plugs, seats, bodies, and other critical valve components.

Tooling, Workholding, and Fixture Improvement

• Assist with the design, build, modification, and implementation of tooling, fixtures, work aids, and setup aids required to improve process performance.
• Identify practical methods to reduce setup variation, improve repeatability, reduce handling risk, improve ergonomics, and make correct execution easier.
• Support evaluation of tooling and fixture performance during production trials and improvement projects.

CANDIDATE REQUIREMENTS

Knowledge, Skills & Abilities

• Working knowledge of manufacturing operations, production workflows, operational excellence, quality systems, safety requirements, and performance management in a production environment.
• Ability to analyze production processes, workflows, constraints, and performance metrics to identify opportunities for improvement.
• Ability to develop, lead, and implement improvement initiatives that increase productivity, quality, throughput, safety, cost-effectiveness, and equipment effectiveness.
• Strong analytical and problem-solving skills, including the ability to conduct root cause analysis, evaluate data, identify trends, and implement sustainable corrective actions.
• Ability to monitor, interpret, and report on key performance indicators, including yield, scrap rates, downtime, cycle times, throughput, and other operational metrics.
• Strong project management skills, including the ability to plan, organize, prioritize, execute, and follow through on multiple improvement projects.
• Ability to develop, implement, and sustain standard operating procedures, standard work, process controls, and best practices.
• Ability to support automation, digital transformation, data collection, and process visibility initiatives where applicable.
• Strong communication and presentation skills, including the ability to prepare reports, present improvement results, communicate cost savings, and explain technical or operational concepts clearly.
• Proficiency with Microsoft Office applications, data analysis tools, ERP/MRP systems, production reporting systems, or other business systems used to track and improve operational performance.
• Ability to demonstrate ownership, accountability, teamwork, and a continuous improvement mindset in support of operational excellence and first-time quality.

Preferred Technical Experience

• Experience in complex, low-volume / high-mix manufacturing.
• Experience with valve manufacturing or similarly complex precision mechanical products.
• Strong background in one or more of the following: welding, manual machining, CNC machining, toolmaking, fixture development, manufacturing troubleshooting, or production process improvement.
• Practical knowledge of welding processes such as GTAW, SMAW, GMAW, hardfacing, cladding, or hot-wire GTAW.
• Familiarity with difficult-to-weld or difficult-to-machine materials, including nonferrous alloys, nickel alloys, copper-nickel, nickel-copper, cobalt-chrome, aluminum bronze, or similar materials.
• Familiarity with CNC machining, manual machining, turning, milling, boring, grinding, or other precision manufacturing processes.
• Familiarity with military, Navy, nuclear, aerospace, or similarly strict quality and documentation environments.
• Experience supporting tooling, fixture, workholding, setup reduction, or manufacturing cell improvement efforts.
• Familiarity with weld procedure qualifications, welder performance qualifications, welding audits, or weld compliance requirements is a plus.
• AWS CWI, welding certifications, machining credentials, toolmaker experience, or equivalent demonstrated technical expertise is a plus.

Education and Experience

• Minimum of 10 years of hands-on manufacturing experience in welding, machining, tooling, manufacturing troubleshooting, or production process improvement.
• Experience in a complex manufacturing environment with strict quality, safety, documentation, and customer requirements preferred.
• Equivalent combinations of technical training, certifications, and hands-on experience may be considered.

Other

• US Citizen