Project and Continuous Improvement Engineer

This position is responsible for leading project engineering, environmental and safety compliance support, and plant-wide continuous improvement strategy. The role combines hands-on project execution with Lean/Six Sigma leadership to improve OEE, product quality, waste reduction, energy conservation, safety, equipment performance, and operating costs.

Qualified candidates must be self-starters with strong leadership, communication, problem-solving, and organizational skills. The position works closely with Operations, Maintenance, Engineering, Environmental, Quality, Lean/CI, supervisors, hourly associates, corporate resources, and outside contractors to identify opportunities, develop solutions, manage projects, and sustain improvements across the facility.

Project Engineering

• Manage environmental, facility, equipment, and process improvement projects from concept through completion, including scope, justification, cost estimates, schedules, budgets, implementation, startup, and closeout.
• Execute capital and expense projects on time and within budget, including assisting with CER preparation and project requirement definition.
• Coordinate project activities involving maintenance resources, salaried and hourly employees, contractors, plant operations, and corporate staff.
• Work from concepts to create equipment designs or process improvements.
• Develop and maintain plant site drawings, equipment drawings, process flow diagrams, electrical prints, and other technical documentation.
• Develop new concepts, techniques, equipment upgrades, and process-control improvements to increase efficiency, quality, throughput, and equipment performance.
• Determine necessary actions and delegate resources effectively to increase safety, quality, OEE, efficiency, and cost performance.
• Perform FMEA, Root Cause Failure Analysis, troubleshooting, and other structured problem-solving methods to resolve equipment, process, and quality issues.

Continuous Improvement & Lean/Six Sigma

• Develop and implement a plant-wide Lean/Six Sigma and continuous improvement strategy with goals, objectives, timetables, action plans, and hourly and salaried leader engagement strategies.
• Lead and support continuous improvement activities aligned with business goals, including safety, OEE improvement, product quality, waste reduction, energy conservation, and operating-cost reduction.
• Coordinate plant-level Lean/Six Sigma initiatives with Element Resources continuous improvement initiatives to optimize resources and minimize redundant efforts.
• Conduct daily plant walk-throughs and inspections with functional leaders, supervisors, and hourly associates to identify improvement opportunities and develop justifications for potential cost savings.
• Conduct time and motion studies, value stream mapping, process charting, production standard validation, and workflow analysis to troubleshoot and streamline plant processes.
• Work with Production, Lean/CI, Maintenance, Engineering, Environmental, and Quality teams to plan and execute Kaizen events and other improvement activities.
• Train and mentor leadership, engineering staff, supervisors, and hourly associates in Lean principles, 5S, Six Sigma methods, standard work, change management, and continuous improvement tools.

Safety, Environmental & Compliance

• Assist in development and implementation of safety protocols, environmental compliance systems, and manufacturing strategies.
• Work with plant operations and Environmental personnel to implement systems that ensure compliance with required Environmental and Safety regulations.
• Participate in training and development programs related to environmental, health, and safety issues.
• Support development, revision, training, and adherence to SOPs, work instructions, standard operating procedures, and safety rules for new and existing equipment and processes.

Leadership, Communication & Documentation

• Provide support and, at times, direct supervision of hourly and/or salaried employees and outside contractors.
• Lead and/or participate in training of supervisory and hourly staff on SOPs, Lean/CI methods, equipment changes, and process improvements.
• Integrate projects and assignments with other departments to support plant priorities and change management processes.
• Prepare reports, business correspondence, procedure manuals, project documentation, cost justifications, and presentations for management and corporate staff.
• Present information and respond to questions from groups of managers, vendors, and employees, as required.
• Perform other duties as directed by the Engineering and Maintenance Manager or Plant Manager.

Required

• Bachelor’s degree in mechanical engineering, Electrical Engineering, Industrial Engineering, or another applicable engineering discipline required.

• Strong verbal and written communication skills, interpersonal skills, leadership ability, and ability to work with individuals from varied backgrounds, skill levels, and education levels.

• Proficiency with Microsoft Office products, including Excel, PowerPoint, Project, Outlook, and Word.

• Strong decision-making skills with ability to evaluate current and future business needs related to safety, quality, production, efficiency, and cost.

• Logical and efficient problem-solving, troubleshooting, root-cause analysis, and data-based decision-making skills.

• Ability to manage multiple projects simultaneously, and work without immediate supervision.

• Ability to read, analyze, and interpret technical procedures, safety rules, operating and maintenance instructions, procedure manuals, and governmental regulations.

• Ability to define problems, collect data, establish facts, draw valid conclusions, and interpret technical instructions in mathematical or diagram form.

• Experience with Lean Manufacturing, Toyota Production Systems, 5S, Kaizen, value stream mapping, time and motion studies, or Six Sigma certification.

• Strong mathematical, analytical, and reasoning skills, including the ability to interpret technical data, apply statistical and practical problem-solving methods, analyze process performance, define problems, collect and evaluate data, identify root causes, and draw sound conclusions to support manufacturing, engineering, and continuous improvement decisions.

Preferred

• One to five years of manufacturing experience in an engineering, maintenance, project, or continuous improvement role; metal processing experience preferred.

• Experience with PLC programming, Allen-Bradley controls, environmental controls, maintenance software such as Leaning2Lean, or similar systems.

• Experience with reverberatory furnaces, blast furnaces, furnace operations, or metal processing equipment.

• Experience developing SOPs, production standards, capital requests, equipment designs, and plant-level improvement roadmaps.

• AutoCAD or comparable drafting/documentation tools.

• Proficiency or working knowledge in hydraulic, pneumatic, mechanical, electrical, process-control, and manufacturing operations.

Physical Requirements & Work Environment

• While some work will be performed in an office setting, significant time will be required in the manufacturing facility, where exposure to noise, fumes, dust, airborne particles, production equipment, and other plant conditions is likely.

• Noise levels in the manufacturing facility are usually high.

• All employees are required to wear required PPE, which will include a full-face respirator inside the manufacturing facility.

• Qualified candidates must be able to sit, stand, walk, bend, climb, and move through the manufacturing facility with minimal effort.

• Must be able to lift 50 pounds.

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Element Resources is an equal opportunity employer where an applicant's qualifications are considered without regard to race, color, religion, sex, national origin, age, disability, veteran status, genetic information, sexual orientation, gender identity or expression, or any other basis prohibited by law.