REPORTS TO: Engineering and Maintenance Manager
JOB PURPOSE:
The Continuous Improvement Engineer is responsible for driving operational excellence across manufacturing processes. This role leads initiatives to improve safety, quality, delivery, and cost through lean manufacturing, Six Sigma methodologies, and data-driven problem solving. This role often facilitates and leads improvement teams and fosters a culture of continuous improvement.AUTHORITY:
All employees have the authority to stop operations/production for the following three reasons: 1) a quality defect, 2) an unsafe act, or 3) a health hazard.ESSENTIAL DUTIES AND RESPONSIBILITIES
- Lead continuous improvement initiatives targeting scrap reduction, cycle time optimization, and OEE improvement in injection molding operations
- Analyze and improve rubber and plastic molding processes, including sealing system components (e.g., gaskets, weatherstrips, O-rings)
- Implement Lean Manufacturing tools (5S, Kaizen, Value Stream Mapping, SMED, Kanban)
- Conduct root cause analysis using methodologies such as 8D, Fishbone, and 5 Whys
- Partner with production, quality, maintenance, and engineering teams to resolve process inefficiencies
- Optimize tooling performance and mold changeover times
- Support APQP, PPAP, and FMEA activities for new and existing products
- Improve process capability (Cp, Cpk) and reduce variation in molding operations
- Drive standard work development and documentation
- Monitor KPIs and develop dashboards to track improvement progress
- Lead or support automation and process digitization initiatives
- Ensure compliance with IATF 16949 and customer-specific requirements
- Provides support and training on CI methodologies and tools to employees at all levels.
- Supports the implementation of changes and ensure they are effectively adopted.
- Collaborate with cross-functional teams to identify opportunities for improvement and ensure alignment.
- Maintains documentation of processes and track key performance indicators (KPIs).
- Participate in new product launch and assist and/or establish new part process and parameters
- Provides input for design of Pre-launch activities for equipment, fixtures, jigs, and tooling.
- Development of Equipment Statement of Requirements.
- Support other departments by collecting, analyzing, and presenting data necessary for decision-making.
- Offer technical assistance and advice to other departments
- Help improve process capability and improve quality rates
- Troubleshoot and resolve issues.
- Lead new process and material development initiatives.
- Develop standard operating procedures for new and existing processes.
- Performs product/process analysis for cost reduction, quality improvement, and improved
- Performs research, design, and development of manufacturing processes including production flow, assembly methods, and production equipment.
- Develop and refine new and existing manufacturing processes.
- Provide daily manufacturing support and develop new manufacturing processes.
- Lead process design and modification efforts to improve plant productivity, reduce cycle time, reduce scrap and rework costs, and lower overall costs.
- Must have working knowledge of the Core Tools used to support the Quality Management system, including but not limited to, problem solving, product launches, and continuous improvement activities.
- Responsible for working with the Engineering and Quality departments to ensure compliance to the change management process; must have working knowledge of product deviation release, technical change process, CTM project.
- Provide daily production support and develop new production processes.
- Lead efforts to improve plant productivity, reduce cycle time, reduce scrap and rework costs, and lower overall costs.
- Data entry into systems and spreadsheets
- Updates and distributes daily reports to senior management including graphs, charts, and PowerPoint presentations
QUALIFICATIONS
Experience, Competencies and Education
Required:
- Bachelor’s degree in Engineering (Mechanical, Industrial, Manufacturing, or related field)
- 2–5+ years of experience in automotive manufacturing
- Experience with Lean, Six Sigma (Green Belt or Black Belt preferred)
- Proficiency in data analysis (Excel, Minitab, or similar tools)
- Familiarity with IATF 16949, APQP, PPAP, FMEA, SPC
- Ability to troubleshoot and maintain manufacturing equipment.
- Proven track record of process improvements.
- Must have high level of interpersonal and statistical analysis skills
- Must be comfortable communicating with and training both in a one-on-one setting and with large groups of people
- Must be willing to work flexible hours as needed to meet production needs (off-shifts, weekends.)
Desired:
- Hands-on experience with plastic or rubber injection molding processes
- Strong knowledge of automotive sealing systems manufacturing
- Possess knowledge of injection molding machines
- Possess knowledge of rubber injection molding process
Language Skills
- Ability to read, analyze, and interpret the most complex documents. Ability to respond effectively to the most sensitive inquiries or complaints.
PHYSICAL DEMANDS
- The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
- While performing the duties of this job, the employee is occasionally required to stand; walk; sit; use hands to finger, handle, or feel objects, tools or controls; reach with hands and arms; talk or hear. The employee must occasionally lift and/or move up to 50 pounds. The noise level in the work environment is usually quiet.
