Continuous Improvement Engineer

Role Summary

The Lean Operations & Continuous Improvement Engineer drives process excellence, waste elimination, and productivity improvement across manufacturing and support functions. The role leads kaizens, valuestream mapping, standard work, problemsolving (A3/8D), and visual management, while building a culture of daily improvement. Partnering with Production, Maintenance, Quality, Supply Chain, and EHS, the role ensures measurable gains in throughput, OEE, quality, safety, ontime delivery, and cost.

Key Responsibilities

A. Lean Transformation & Project Delivery

• Lead identification, prioritization, and execution of CI projects using Lean, Kaizen, 5S, TPM, SMED, and Six Sigma methodologies to reduce waste (TIMWOOD) and improve flow.
• Conduct Value Stream Mapping (VSM) and create improvement roadmaps (futurestate design, takttime balancing, line relayout, supermarket/pull/Kanban).
• Run SMED events to cut changeover times; design standard work and visual controls (andon, heijunka boards).
• Facilitate A3 and 8D problem solving; drive robust root cause analysis (5 Why, Fishbone) and sustainable corrective actions.

B. Performance Management & Analytics

• Define and track KPIs: OEE, FPY/FTT, Scrap/Defect ppm, Lead Time, Inventory Turns, Changeover Time, Schedule Adherence, OTIF, Energy per Unit.
• Build dashboards/MIS with daily tier reviews; ensure data integrity and action closure through PDCA.

C. Quality, Standardization & Compliance

• Collaborate with QA to strengthen process capability (Cp/Cpk), SPC charts, and control plans; reduce variability and rework.
• Author and maintain SOPs/Work Instructions, PFMEA updates, and standardized checklists.
• Support audits and certifications (e.g., ISO 9001/14001/45001, IATF where applicable).

D. ShopFloor Enablement & Culture

• Coach supervisors, cell leaders, and operators on Lean tools; run kaizen blitzes and 5S audits.
• Lead Daily Management System (DMS) / tier meetings and visual factory deployment.
• Partner with HR/L&D for Lean capability building (training calendars, belt programs).

E. Supply Chain & Maintenance Synergy

• Improve material flow: milkruns, pointofuse inventory (POUS), Kanban sizing, and space optimization.
• Work with Maintenance on TPM pillars (Autonomous & Planned Maintenance) to cut unplanned downtime and enhance MTBF/MTTR.

F. Safety & EHS

• Integrate CI with safety standards; address hazards via JSA/JHA, pokayoke, and ergonomic improvements.

Qualifications

• B.E./B.Tech in Mechanical/Industrial/Production/Electrical (or related).
• 38 years of handson CI/Lean experience in a manufacturing environment (discrete or process).
• Demonstrated delivery of measurable improvements (cost, OEE, quality, lead time).
• Working knowledge of Lean, Kaizen, 5S, VSM, SMED, TPM, SPC, MSA, PFMEA, and problemsolving methods (A3/8D/5 Why).

Nice to Have

• Lean Six Sigma Green Belt/Black Belt certification.
• Exposure to ERP/MES data, Power BI/Excel analytics; familiarity with AutoCAD/plant layouting.
• Experience with IATF 16949 (automotive) or GMP (process industries), as relevant.

Key Competencies

• Strong analytical & statistical mindset; datadriven decision making.
• Handson facilitation on the shop floor; ability to influence without authority.
• Structured communicationconcise A3s, visual storytelling, and stakeholder alignment.
• Project & change management; persistence to sustain gains (control plans).

KPIs (Role Scorecard)

• OEE improvement: +X percentage points in 612 months.
• Changeover time (SMED): X% within first two quarters.
• Scrap/defects: X% (ppm reduction) with sustained control.
• Throughput/Lead time: X% lead time or +X% line capacity via flow improvements.
• Inventory turns: +X turns through pull/Kanban.
• Cost savings: /$/ X via CI portfolio, validated by Finance.
• 5S audit score: achieve X and sustain across zones.
• Training & culture: # of kaizens/person/year; % workforce trained/certified.

Tools & Systems

• Lean toolkit (VSM, A3, SMED, 5S, Kanban, Heijunka, PokaYoke, Andon)
• Problem solving (8D, 5 Why, Fishbone), SPC/Capability (Cp/Cpk)
• Data & visualization: Excel/Power BI; ERP/MES; basic CAD for layouts

Travel / Shift

• Shopfloor intensive; occasional travel across plants/vendors.
• Willingness to work flexible shifts during trials/kaizen events.