Sr. Continuous Improvement Engineer

The Continuous Improvement Engineer works cross-functionally with Production, Maintenance, Quality, Engineering, Supply Chain, and other departments to identify root causes, develop solutions, and ensure improvements are sustained over time. Key Responsibilities Lead continuous improvement projects focused on process efficiency, productivity, quality, cost reduction, and waste elimination.Analyze production data, downtime, scrap, labor, cycle times, and other operational metrics to identify improvement opportunities.Conduct root-cause analysis using 5 Why, Fishbone, Pareto, FMEA, and other problem-solving methodologies.Implement Lean Manufacturing tools including 5S, Kaizen, Standard Work, Value Stream Mapping, Visual Management, SMED, and TPM.Develop and track project KPIs to measure improvement results and ensure long-term sustainability.Partner with operations and maintenance teams to improve equipment reliability, uptime, and overall equipment effectiveness (OEE).Optimize manufacturing layouts, material flow, workstations, staffing, and production processes.Develop and maintain standard work, process documentation, work instructions, and process control plans.Identify opportunities for automation, ergonomic improvements, labor optimization, and material waste reduction.Lead Kaizen events and facilitate cross-functional improvement teams.Develop business cases and calculate ROI, cost savings, labor savings, and payback for improvement projects.Support new equipment, tooling, product launches, and process changes.Collaborate with Quality to reduce defects, rework, scrap, and customer complaints.Train employees and supervisors on Lean principles, problem-solving techniques, and standardized processes.Ensure improvement projects meet company safety, quality, environmental, and regulatory requirements.Report on project status, results, risks, and recommendations to management.Establish controls and follow-up activities to ensure improvements remain effective.Engage fully in plant safety protocols and environmental compliance.