Process Improvement Engineer, Continuous Improvement Engineer

Summary:

This job is responsible for understanding the current process state, identifying efficiency/improvement opportunities, then leading cross-functional team members to drive process improvements tied to Key Performance Indicators (KPIs) of the business using continuous improvement processes, methods and tools. 

This position will analyze and audit processes in order to make recommendations on equipment design, safety, quality, cost, waste reduction, process reliability, efficiency, environmental impact & compliance, and energy reductions and the like. 

Essential Duties and Responsibilities:

• Other duties may be assigned.
• Abide by, enforce and participate fully in the implementation and ongoing oversight of all company safety standards and regulations.
• Provide input into the development of manufacturing strategy by defining the current condition of the manufacturing operations to identify opportunities and create a target condition, with action plans to improve operational and financial results
• Improve, develop, and implement production/processing methods and controls to reduce cost and elevate quality standards in a safe and cost effective manner by having a thorough understanding of all factors and conditions that impact the processes and products, including safety and environmental impacts. Provide troubleshooting, problem analysis and technical support to the plant as requested. Use continuous improvement methods, techniques, and procedures such as daily management, problem solving, DMAIC, etc, to lead and facilitate continuous improvement.
• Evaluate and prioritize process improvement activities by using various financial, production and labor data. Manage multiple projects with varying degrees of priorities effectively through the use of sound project management skills. 
• Gain support for, and facilitate the implementation of revisions to methods of operation, material handling, equipment layout, or other changes to increase production, improve standards and achieve optimum quality within the limitations of equipment.
• Review and recommend equipment specifications, performance requirements, cost analysis, and proposals for integrating machinery, equipment, and tooling into the manufacturing process.
• Analyze problems and implement solutions using critical thinking skills and focused improvement methods. Incorporate creative thinking into the problem solving approach to identify unique and different ways to make things better/more consistent/faster/cheaper/efficient
• Lead and coach others in determining specific measures of performance and productivity improvements. Provide training and consultative assistance for all levels of the organization.
• Develop and maintain written standards, work instructions and quality check points on the production processes, and all improvements. 
• Liaison with relevant business units and departments in the implementation of continuous improvement processes/initiatives. Work with Training Unit for the training plan of affected employees on improvements and new methods/processes of production. Facilitate training as needed.
• Communicate progress and successes within the location and within the business unit. Maintain, compile, analyze, and report metrics of improvement projects.
• Recommend and assist in the establishment and implementation of environmental and safety procedures, identification and review safety issues, review safety and accident reports, and implementation of corrective action. 
• Provide input into the planning work assignments in accordance with worker performance, machine capacity, production schedules, or anticipated delays.

Competency:

• To perform the job successfully, an individual should demonstrate the following competencies:
• Safety and Security - Observes safety and security procedures, Determines appropriate action beyond guidelines, Reports potentially unsafe conditions, Uses equipment and materials properly
• Analytical - Synthesizes complex or diverse information, Collects and researches data, Uses intuition and experience to complement data, Designs work flows and procedures
• Design - Generates creative solutions; Translates concepts and information into images, Uses feedback to modify designs, Applies design principles, Demonstrates attention to detail
• Problem Solving - Identifies and resolves problems in a timely manner, Gathers and analyzes information skillfully, Develops alternative solutions, Works well in group problem solving situations, Uses reason even when dealing with emotional topics
• Project Management - Develops project plans, Coordinates projects, Communicates changes, Completes projects on time and budget and progress, Manages project team activities
• Technical Skills - Assesses own strengths and weaknesses, Pursues training and development opportunities, Strives to continuously build knowledge and skills, Shares expertise with others
• Customer Service - Manages difficult or emotional customer situations, Responds promptly to customer needs Solicits customer feedback to improve service, Responds to requests for service and assistance, Meets commitments
• Interpersonal - Focuses on solving conflict, not blaming; Maintains confidentiality, Listens to others without interrupting, Keeps emotions under control, Remains open to others' ideas and tries new things
• Oral Communication - Speaks clearly and persuasively in positive or negative situations, Listens and gets clarification, Responds well to questions, Demonstrates group presentation skills, Participates in meetings
• Team Work - Balances team and individual responsibilities, Exhibits objectivity and openness to others' views Gives and welcomes feedback, Contributes to building a positive team spirit, Puts success of team above own interests, Able to build morale and group commitments to goals and objectives, Supports everyone's efforts to succeed, Recognizes accomplishments of other team members
• Written Communication - Writes clearly and informatively, Edits work for spelling and grammar, Varies writing style to meet needs, Presents numerical data effectively, Able to read and interpret written information
• Change Management - Develops workable implementation plans, Communicates changes effectively, Builds commitment and overcomes resistance, Prepares and supports those affected by change, Monitors transition and evaluates results
• Quality Management - Looks for ways to improve and promote quality, Demonstrates accuracy and thoroughness
• Business Acumen - Understands business implications of decisions, Displays orientation to profitability, Demonstrates knowledge of market and competition, Aligns work with strategic goals
• Cost Consciousness - Works within approved budget, Develops and implements cost saving measures, Contributes to profits and revenue, Conserves organizational resources
• Diversity - Demonstrates knowledge of EEO policy, Shows respect and sensitivity for cultural differences, educates others on the value of diversity, Promotes a harassment-free environment, Builds a diverse workforce
• Ethics - Treats people with respect, keeps commitments, Inspires the trust of others, Works with integrity and ethically, Upholds organizational values
• Organizational Support - Follows policies and procedures, Completes administrative tasks correctly and on time, Supports organization's goals and values, Benefits organization through outside activities, Supports affirmative action and respects diversity
• Strategic Thinking - Develops strategies to achieve organizational goals, Understands organization's strengths & weaknesses, Analyzes market and competition, Identifies external threats and opportunities, Adapts strategy to changing conditions
• Adaptability - Adapts to changes in the work environment, Manages competing demands, Changes approach or method to best fit the situation; Able to deal with frequent change, delays, or unexpected events
• Attendance/Punctuality - Is consistently at work and on time, Ensures work responsibilities are covered when absent, Arrives at meetings and appointments on time
• Dependability - Follows instructions, responds to management direction, Takes responsibility for own actions, Keeps commitments, Commits to long hours of work when necessary to reach goals, Completes tasks on time or notifies appropriate person with an alternate plan
• Initiative - Volunteers readily, Undertakes self-development activities, Seeks increased responsibilities, Takes independent actions and calculated risks, Looks for and takes advantage of opportunities, Asks for and offers help when needed
• Innovation - Displays original thinking and creativity, Meets challenges with resourcefulness, Generates suggestions for improving work, Develops innovative approaches and ideas, Presents ideas and information in a manner that gets others' attention
• Judgment - Displays willingness to make decisions, Exhibits sound and accurate judgment, Supports and explains reasoning for decisions, Includes appropriate people in decision-making process, Makes timely decisions
• Motivation - Sets and achieves challenging goals, Demonstrates persistence and overcomes obstacles, Measures self against standard of excellence, Takes calculated risks to accomplish goals
• Planning/Organizing - Prioritizes and plans work activities, Uses time efficiently, Plans for additional resources, Sets goals and objectives, Organizes or schedules other people and their tasks, Develops realistic action plans
• Professionalism - Approaches others in a tactful manner, Reacts well under pressure, Treats others with respect and consideration regardless of their status or position, Accepts responsibility for own actions, Follows through on commitments
• Quality - Demonstrates accuracy and thoroughness, Looks for ways to improve and promote quality, Applies feedback to improve performance, Monitors own work to ensure quality
• Quantity - Meets productivity standards, Completes work in timely manner, Strives to increase productivity, Works quickly

Qualifications:

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Education/Experience:

Bachelor's degree in Chemical, Mechanical, Electrical Engineering, or related field from four-year college or university; and over 2 years up to and including 4 years’ manufacturing experience. Significant experience applying/implementing Lean, TOC, Six Sigma or other TQM process improvement methodologies required.

Language Ability:

Ability to read, analyze, and interpret common scientific and technical journals, financial reports, and legal documents. Ability to write articles for publication that conform to prescribed style and format. Ability to effectively present information to top management, public groups, and/or boards of directors.

Math Ability:

Ability to apply advanced mathematical concepts such as exponents, logarithms, quadratic equations, and permutations. Ability to apply mathematical operations to such tasks as frequency distribution, determination of test reliability and validity, analysis of variance, correlation techniques, sampling theory, and factor analysis.

Reasoning Ability:

Ability to apply principles of logical or scientific thinking to a wide range of intellectual and practical problems. Ability to deal with nonverbal symbolism (formulae, scientific equations, graphs, etc.,) in its most difficult phases. Ability to deal with a variety of abstract and concrete variables.

Computer Skills:

To perform this job successfully, an individual should have proficiency in the use of: 

Microsoft Office Suite products (Word, Excel, PowerPoint, Outlook, etc.), Enterprise Resource Planning (ERP) Software; Manufacturing software.

Other Skills, Knowledge & Abilities:

• Effective motivator who can engage a diverse group of associates (operators to directors) in the problem solving process.
• High level of competency in obtaining, analyzing, applying and presenting data to educate and influence, leveraging tools such as databases, spreadsheets and other business systems and software.
• Ability and willingness to work flexible hours and shifts if requested, including weekends and nights to support the business.
• Experience in textiles, specifically process engineering relating to blow room, cleaning, carding equipment and filtration.
•  Experience in team development, able to train maintenance & operators.

Supervisory Responsibilities:

This job has no supervisory responsibilities.

Physical Demands:

The physical demands described here are representative of those that must be met by an associate to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the associate will be engaging in these physical activities:

Physical Activity Amount of Time

Stand X 

Walk X 

Sit X 

Use hands to finger(s), handle, or feel X

Reach with hands and arms X 

Climb or balance X  

Stoop, kneel, crouch, or crawl X  

Talk or hear X

Taste or smell X

The job requires the individual to be able to move about the plant on a regular basis to talk with and obtain information from other associates, may participate in physical inventory activities, and work for long periods of time sitting and using a computer and telephone.

This job requires that the person be able to independently lift or exert the amount of force or weight within the frequency specified below:

Lifting or Force Requirements Amount of Time

Up to 10 pounds X

Up to 25 pounds X 

Up to 50 pounds X  

Up to 100 pounds X   

More than 100 pounds X   

This job performs Medium Work. It requires the exertion of 20 to 50 pounds of force occasionally, and/or 10 to 25 pounds of force frequently, and/or greater than negligible up to 10 pounds of force constantly to move objects. 

This job requires normal or corrected vision to be performed successfully.

Work Environment:

The work environment characteristics described here are representative of those an associate encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

The noise level in the work environment is usually mild to moderate.

This job will be performed under the environmental factors given below:

Environment Conditions Amount of Time

Wet or humid conditions (non-weather) X 

Work near moving mechanical parts X 

Work in high, precarious places X  

Fumes or airborne particles X  

Toxic or caustic chemicals X 

Outdoor weather conditions X  

Extreme cold (non-weather) X   

Extreme heat (non-weather) X   

Risk of electrical shock X   

Work with explosives X   

Risk of radiation X   

Vibration X   

This job has dual work locations. Job duties and responsibilities are performed in both the office setting as well as in manufacturing or warehouse areas. The job requires that the individual holds a valid driver’s license and be able to operate a motor vehicle, as well as travel by car or air occasionally, including overnight stays.

The work environment characteristics described above necessitates the use of Personal Protective Equipment (PPE) such as safety glasses/goggles, gloves, closed shoes, respirator and other protective equipment as specified by OSHA and other federal/state regulations. The employee must wear the prescribed personal protective equipment at all times while performing the duties of this job, and as specified or designated in production or warehouse areas.

 Barnhardt Manufacturing Company is an Equal Employment Opportunity Employer (EOE/including disability/vets)