Principal Continuous Improvement Engineer - LEAN MANUFACTURING

Process Re-Engineering, Continuous Improvement and Change Management

• Analyze current processes by generating Process Flow Diagrams and Value Stream Maps in order to benchmark and/or quantify current performance, identify and quantify waste, and to establish metrics for quantifying the improvement activities.
• Initiate, oversee and drive team-based problem-solving methodologies such as Global 8-D (special cause) and DMAIC (common cause) to resolve real-time issues that are negatively impacting Quality Key Performance Indicators, such as Plant Performance Average and Average Outgoing Quality.
• Identify and minimize process waste by leading and organizing Kaizen events centered on Value Stream Mapping, Poka-Yoke, Jikoka, Single Minute Exchange of Die, and Visual Management Systems.
• Achieve significant improvements in Operational Efficiency by implementing Kanban systems, Heijunka production planning, and Standardized Work manufacturing practices.
• Adhere to the Six Sigma DMAIC process methodology to define, measure, analyze, improve and control “common cause" manufacturing issues.
• Support the execution of studies to stabilize, characterize, and optimize key process parameters. Champion the implementation and sustained use of Statistical Process Control methods.
• Develop training materials, and administer improvement workshops for process re-engineering projects in our Club Manufacturing, Raw Materials and Finished Goods Warehousing, Supply Chain Management and Process Engineering business processes.
• Demonstrate deep Project Planning skills to accurately estimate work effort and resources needed to execute initiatives.
• Use various Change Management strategies to overcome organizational roadblocks to achieve desired change levels and review outcomes for effectiveness.
• Apply techniques that support and sustain employee enthusiasm and implement strategies that enable parties with different or opposing outlooks to recognize common goals and work together to achieve them.

• Work with internal and external resources to develop club manufacturing equipment and systems to optimize processing performance.
• Provide process performance baseline data and anticipated target performance during the specification of new capital equipment.
• Develop business cases by calculating Return on Investments (ROI), Return on Assets (ROA), and Net Present Value (NPV) analyses.
• Measure and monitor project activity by using tools such as cost variance analysis, milestones and actual vs. planned budgets to monitor activity against the committed plan.

• General knowledge of manufacturing processes required.
• Proficient with MS Word, PowerPoint, Access, and Excel
• Solid knowledge of statistical tools and Minitab software.
• Able to manage multiple tasks
• Able to read and interpret instructions, procedures, etc.
• Team player with exemplary communication skills.
• Flexible and able to adapt to changing environments and priorities and function without rigid organizational boundaries.
• Must show evidence of increasing responsibility with years of experience.
• Must be able to demonstrate a successful track record.
• Highly energetic, creative, intelligent, and logical.
• Able to work extended hours in critical situations.

Education and/or Experience

• BS in Chemical, Mechanical, Manufacturing, Industrial Engineering or relevant business discipline required and/or equivalent experience.
• Masters degree in Engineering or Business is desirable.
• Minimum 8 years experience (or Master’s degree equivalent) demonstrating skills in the above duties.
• Lean knowledge/experience to apply lean concepts and principles across an entire value stream. Lean certification is highly desirable
• Project management experiences
• Six Sigma Green or Black Belt certification is highly desirable.