Continuous Improvement Engineer

Continuous Improvement Engineer

Position Objective

The Continuous Improvement Engineer serves as a process subject matter expert (SME) for manufacturing operations and plays a key role in leading and supporting the shift toward a sustainable Lean culture. This position focuses on stabilizing processes, bringing them under control, and sustaining improvements over time through lean manufacturing, structured problem solving, data-driven analysis, collaboration, and the effective use of automation supported by ROI justification.

Key Responsibilities

Process Ownership & Continuous Improvement

• Serve as a process subject matter expert for assigned manufacturing processes, understanding process flow, capability, constraints, and risks.
• Lead efforts to bring processes into statistical control and sustain gains using standard work, control plans, SPC, and visual management.
• Recommend and implement improvements to production processes, methods, and controls.
• Apply analytical and creative thinking to solve manufacturing problems and improve performance.

Lean Culture & Change Leadership

• Lead, support, and facilitate the ongoing shift toward a Lean culture across the organization.
• Act as a coach and change agent by helping teams understand why Lean practices are used, not just how.
• Encourage employee engagement and ownership of continuous improvement at all levels.
• Partner with leaders and teams to reinforce Lean behaviors, standard work, and continuous improvement routines.
• Help embed Lean thinking into daily management systems and decision-making.

Structured Problem Solving

• Utilize at least one structured problem-solving methodology, such as:
  • DMAIC
  • PDCA
  • Shainin Red X
• Define problems clearly, identify and validate root causes, implement effective solutions, and establish controls to sustain results.
• Support team-based problem-solving activities and knowledge sharing.

Lean Manufacturing & Kaizen

• Apply lean manufacturing principles and tools, including:
  • 5S and visual workplace
  • Kaizen activities and events
  • Standard work
  • Kanban and pull systems
  • Takt time analysis, line balancing, and line pacing
  • Waste identification and elimination
• Facilitate and participate in cross-functional Kaizen events, recognizing the value of collaboration across Operations, Engineering, Quality, Maintenance, and Supply Chain.
• Support continuous improvement through hands-on involvement in shop-floor activities.

Manufacturing Systems, Layout & Methods

• Plan, design, implement, and improve manufacturing systems that support performance, reliability, maintainability, schedule adherence, and cost control.
• Establish methods, equipment, and layouts for direct and indirect labor using time studies and predetermined time systems (e.g., MTM).
• Analyze layouts, material flow, and work methods; recommend changes to improve safety, efficiency, and throughput.
• Prepare and maintain process documentation and manufacturing layouts.

Equipment, Automation & ROI Justification

• Identify opportunities for tooling, equipment upgrades, and industrial automation to improve process capability, ergonomics, quality, and labor efficiency.
• Design, develop, test, source, and implement machinery, tooling, fixtures, and equipment.
• Support equipment procurement and implementation, including installation and process validation.
• Develop ROI and cost-justification analyses for capital and improvement projects, including savings estimates and payback considerations.

Data, SPC & Performance Management

• Implement and maintain Statistical Process Control (SPC) for variable and attribute data.
• Use data analysis to support cost reduction, quality improvement, and efficiency efforts.
• Support teams in understanding and using KPIs to monitor and improve process performance.

New Product & Process Launch

• Coordinate maufacturing launches for new or revised products, including goal setting, training, and performance evaluation.
• Participate in concurrent engineering and design reviews to support manufacturability and robust process design.

Communication, Training & Collaboration

• Participate in production and department meetings.
• Communicate changes and improvements through visual, written, and verbal instructions.
• Train personnel on new processes, systems, and Lean tools as needed.
• Standardize procedures to support consistency and sustained results.

• 3-5 years of experience in a manufacturing or industrial environment.
• Bachelor's degree in Mechanical Engineering , Manufacture Engineering, Industrial Engineering background or equivalent experience considered.
• Experience owning manufacturing processes and supporting process control and sustainment.
• Working knowledge of Lean manufacturing principles and tools.
• Familiarity with at least one structured problem-solving methodology (DMAIC, PDCA, or Shainin Red X).
• Understanding of industrial automation and its application to manufacturing improvement.
• Experience developing or supporting ROI and cost justification for improvement or capital projects.
• Proficiency with Microsoft Excel (pivot tables, charts, trending, data analysis) and familiarity with PowerPoint, Visio, Word, and Outlook.
• Effective communication skills and comfort working cross-functionally.
• Ability to support cultural change while balancing data-driven analysis and practical problem solving.

AAF International is an Equal Opportunity Employer M/F/Disability/Veteran.

We are an equal employment opportunity employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, sex, sexual orientation, gender identity, national origin, citizenship, veteran status, uniform servicemember status, age, disability or any other legally recognized protected personal characteristics.