Quality Engineer / Continuous Improvement Facilitator

Deckorators, a brand of UFP Industries, is a leader in composite decking, railing, and outdoor living products. Our Buffalo, New York plant is the newest and flagship facility utilizing our proven and growing Surestone technology. This state-of-the-art extrusion and polymer manufacturing site will play a major role in advancing our innovation, driving continuous improvement, and scaling our capacity to serve customers nationwide.

The Quality Engineer / Continuous Improvement Facilitator is responsible for driving product and process quality, leading continuous improvement (CI) activities, and supporting a culture of operational excellence at the Buffalo flagship plant.

This role combines traditional quality engineering responsibilities (inspection methods, data analysis, calibration, validation, supplier quality, and corrective actions) with hands-on CI facilitation (Kaizen, VSM, 5S, and waste reduction projects). The Quality Engineer / CI Facilitator will partner closely with Operations, Process Engineering, Maintenance, and Leadership to ensure our extrusion and polymer processes consistently meet Deckorators' standards for safety, quality, and efficiency.

Quality Engineering

• Provide technical support to ensure manufacturing processes and final products meet internal and external quality standards.

• Perform quality inspections, analyze quality data, and implement quality control plans.

• Organize and manage calibration of equipment, gauges, and measurement devices.

• Lead or support validation activities by planning, scheduling, executing, and tracking progress.

• Monitor systems performance and maintain documentation to ensure stable and capable operations.

• Develop, update, and maintain Work Instructions (WI) and quality-related documentation; train team members on quality tools and analysis methods.

• Manage day-to-day quality lab activities and testing processes.

• Implement proactive quality strategies to move from reactive to preventive quality management (e.g., SPC, trend analysis, early-warning indicators).

• Support root cause analysis, corrective and preventive actions (CAPA), internal audits, and customer or third-party audits.

• Monitor supplier quality performance; coordinate activities related to non-conforming materials and supplier corrective actions.

• Prepare regular and special quality reports as required.

Continuous Improvement (CI) & Lean Facilitation

• Establish and help build the plant's Continuous Improvement (CI) team and culture.

• Coordinate the activities of the site's Lean/CI initiatives in partnership with plant leadership.

• Evaluate operations to identify waste, variation, and bottlenecks; prioritize opportunities for improvement.

• Facilitate CI events such as value stream mapping (VSM), Kaizen activities, 5S, and standard work initiatives.

• Develop, implement, and sustain solutions to reduce waste, improve performance, and increase throughput and OEE.

• Document and standardize improvements into procedures, standard work, and visual controls.

• Teach, coach, and mentor employees at all levels in Lean/CI tools, problem-solving, and basic manufacturing principles.

• Develop programs and engagement activities that encourage employee involvement and idea generation for continuous improvement.

• Stay current on CI and quality best practices; attend trainings/seminars as needed and share key learnings with the plant team.

Collaboration & Culture

• Work closely with Operations, Engineering, Maintenance, and Quality teams to support projects and plant initiatives.

• Support the Quality Manager and Plant Leadership in driving a culture of safety, quality, and continuous improvement.

• Communicate clearly and regularly with stakeholders on project status, risks, and results.

• Participate in safety programs and ensure CI and quality activities align with safety standards and company policies.

• Perform other duties as assigned.

Education

• Associate's degree in Quality, Industrial Technology, Engineering Technology, or a related discipline required; Bachelor's degree in Industrial, Mechanical, Manufacturing Engineering, or related field preferred.

Experience

• 2-3+ years of experience in a manufacturing environment (building materials, plastics, extrusion, continuous process, or similar industry preferred).

• Experience in a lean manufacturing or CI-focused environment (exposure to 5S, Kaizen, VSM, standard work, etc.).

Technical Skills

• Hands-on experience with Lean Manufacturing and CI tools such as 5S, value stream mapping, Kaizen, root cause analysis (e.g., 5-Why, Fishbone), and CAPA.

• Strong technical knowledge of quality systems and manufacturing processes; familiarity with continuous process environments is a plus.

• Proficiency with Microsoft Office applications including Excel, Word, and Outlook.

• Experience with data collection, analysis, basic statistics, and creating clear, actionable reports.

• Ability to develop and maintain work instructions, standard work, and visual controls.

Soft Skills & Attributes

• Strong attention to detail and a process-focused mindset.

• Effective communication and interpersonal skills; able to influence without direct authority.

• Comfortable teaching, coaching, and presenting CI and quality concepts to frontline employees and leaders.

• Self-driven, highly motivated, and able to work independently with minimal supervision.

• Ability to manage multiple projects, prioritize tasks, and meet deadlines in a fast-paced environment.

• Team-oriented and aligned with company goals; maintains professionalism in all interactions.

Salary Pay Range:

• $70,000 - $80,000 annually, dependent on experience and local market conditions. *pay range may be adjusted depending on cost of living

Bonus/Incentive Pay:

• Annual performance bonus opportunity based on Company and specific business unit ROI and PBOP achievement criteria and individual job responsibility and performance.

Benefits currently offered to our employees include:

• Medical insurance

• Health savings account (HSA) with company contribution

• Dental insurance

• Vision insurance

• Basic and voluntary life insurance

• Short- and long-term disability insurance

• 401(k) plan with company match

• Paid vacation and holidays

• Employee stock purchase program with discount

• Educational reimbursement

• Wellness programs and challenges

• Other supplemental benefits as offered by the Company