Process Improvement Engineer - Industrial

Role details

Job Summary

The Industrial Process Improvement Engineer is responsible for driving continuous improvement across manufacturing processes, equipment, and support systems to improve safety, quality, productivity, capacity, and cost performance. This position applies engineering principles, data analysis, Lean/Six Sigma methodologies, and hands-on manufacturing expertise to identify opportunities, resolve process issues, optimize equipment, reduce waste, and implement sustainable improvements.

The Engineer works closely with Manufacturing, Quality, Maintenance, Engineering, and other cross-functional teams to troubleshoot equipment and process issues, implement corrective and preventive actions, support new product and equipment launches, and develop standardized processes and training.

Essential Functions

• Lead and support systematic manufacturing performance improvements focused on safety, quality, delivery, productivity, capacity, and cost.
• Troubleshoot, program, optimize, and make process adjustments to injection molding and over-molding equipment.
• Analyze machine and process performance data to identify sources of downtime, scrap, variation, and inefficiency.
• Lead and support scrap-reduction initiatives, including data analysis, process experimentation, root cause investigation, and implementation of sustainable corrective actions.
• Develop, recommend, document, and implement corrective and preventive actions in accordance with established procedures.
• Conduct process optimization studies, capacity analyses, time studies, and detailed engineering evaluations of manufacturing work areas, systems, equipment, and processes.
• Develop and implement process improvement initiatives designed to increase operational efficiency, throughput, productivity, equipment utilization, and overall manufacturing performance.
• Monitor manufacturing trends, KPIs, and process data to identify improvement opportunities and lead cross-functional teams in developing and implementing solutions.
• Partner with Manufacturing and Maintenance to improve equipment changeover processes, reduce changeover time, and establish standardized work methods.
• Apply Lean Manufacturing and Six Sigma principles to eliminate waste, reduce process variation, improve flow, and increase process capability.
• Develop and maintain process documentation, work instructions, standard operating procedures, process specifications, and other engineering documentation as required.
• Assist in developing training materials and provide technical training to manufacturing personnel on equipment, processes, troubleshooting, and standardized work.
• Develop sufficient working knowledge of manufacturing equipment, processes, controls, and operating methods to effectively train employees and support troubleshooting activities.
• Collaborate with equipment manufacturers, automation suppliers, material suppliers, and other vendors to troubleshoot issues and evaluate technical solutions.
• Support the evaluation, installation, commissioning, and optimization of new manufacturing machinery, automation, tooling, and process technologies.
• Participate in new product launches, process development, equipment qualification, production readiness activities, and manufacturing scale-up.
• Use Excel, SPC, and other data-analysis tools to monitor process performance and support data-driven engineering decisions.
• Ensure improvements are properly documented, standardized, and sustained through appropriate process controls and follow-up.
• Work collaboratively with cross-functional teams to identify priorities, resolve issues, and achieve measurable manufacturing improvements.

Secondary Duties

• Support new machinery, automation, tooling, and manufacturing program launches.
• Assist with capital equipment evaluations, justification, installation, commissioning, and process validation as required.
• Participate in engineering, quality, safety, and operational improvement projects as assigned.

Key Performance Areas

Success in this position may be measured through improvements in:

• Safety performance and reduction of process-related safety risks
• Scrap and material waste reduction
• Machine uptime and equipment utilization
• Overall equipment effectiveness (OEE)
• Throughput and production capacity
• Process capability and quality performance
• Changeover time and manufacturing flexibility
• Downtime and recurring equipment/process issues
• Labor and operating efficiency
• Standardization and sustainability of process improvements
• Successful implementation of new equipment, products, and processes

QualificationsEducation

• Bachelor's degree in Engineering, Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or a related technical discipline required.

Required Experience and Technical Skills

• Minimum of 2 years of manufacturing engineering, process engineering, or continuous improvement experience, preferably in extrusion, injection molding, or over-molding environments.
• Demonstrated hands-on experience troubleshooting and optimizing injection molding and/or over-molding equipment.
• Ability to make equipment and process program adjustments and troubleshoot machine/process issues with a strong understanding of injection molding operations.
• Working knowledge of manufacturing processes, equipment controls, process parameters, tooling, materials, and production methods.
• Proficiency with Microsoft Excel and statistical process control (SPC).
• Ability to analyze manufacturing data and translate findings into actionable process improvements.
• Experience with Lean Manufacturing, Six Sigma, structured problem solving, or other continuous improvement methodologies.
• Experience with industrial automation and robotics is a plus.
• Ability to read and interpret engineering drawings, equipment documentation, process specifications, and technical information.

Professional Competencies

• Strong analytical and problem-solving skills with a data-driven approach to decision-making.
• Ability to manage multiple projects and priorities while maintaining accuracy and attention to detail.
• Strong project ownership and follow-through, from identifying an opportunity through implementation and sustainment.
• Ability to work independently and exercise sound engineering judgment.
• Ability to effectively collaborate within cross-functional teams and influence process improvements without direct authority.
• Excellent written, verbal, and interpersonal communication skills.
• Comfortable working in a hands-on manufacturing environment and interacting directly with operators, technicians, supervisors, engineers, and management.
• Ability to communicate technical information clearly to both technical and non-technical audiences.
• Demonstrated commitment to safety, quality, continuous improvement, and operational excellence.

Working Environment

• This position operates in a manufacturing environment and requires regular interaction with production equipment, manufacturing personnel, maintenance teams, and engineering resources.
• May require occasional work outside of normal business hours to support production issues, equipment installations, launches, or critical improvement activities.
• Appropriate personal protective equipment (PPE) must be worn in designated manufacturing areas.
• The position may require standing, walking, and working around manufacturing equipment for extended periods.

Preferred Qualifications

• Experience with injection molding and over-molding processes.
• Experience with extrusion manufacturing.
• Experience with robotics, automation, PLCs, HMIs, or machine controls.
• Lean Manufacturing or Six Sigma certification.
• Experience with OEE, SMED/changeover reduction, process capability, statistical analysis, and DOE.
• Experience with new equipment installation, commissioning, and production launch.
• Experience leading cross-functional continuous improvement projects.
• Experience developing standard work, process documentation, and operator training.

Pay: $70,000.00 - $100,000.00 per year

Benefits:

• Dental insurance
• Employee assistance program
• Flexible schedule
• Flexible spending account
• Health insurance
• Health savings account
• Life insurance
• Paid time off
• Parental leave
• Referral program
• Vision insurance

Experience:

• engineering, process improvement, or related : 2 years (Required)
• production root causes analysis: 2 years (Required)
• improving manufacturing or production processes?: 2 years (Required)
• statistical process controls (SPC): 1 year (Required)

Work Location: In person