Duties and Responsibilities
Employee Training and Awareness:
- Support and assist with development, implementation and leading lean manufacturing training program including, but not limited to, 5S, kaizen, kanban, visual factory and standard work for all levels of employees.
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Learn existing processes to develop and maintain manufacturing standard work associated with fabrication, welding, paint, final assembly and special processes. Assist in the training and evaluation when applicable.
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Audit processes to ensure standards and lean initiatives are being sustained.
- Become a leader and/or participate in PIT (Performance Improvement Team) activities.
- Work with all levels of associates to learn all manufacturing processes from raw materials to final assembly.
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Develop into the role of internal manufacturing process consultant for product groups, management, New Product Development Engineering, Marketing and Sales.
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Build a Lean Manufacturing Culture:
The Continuous Improvement Engineer will act as the lead change agent for lean manufacturing implementation, process improvement and improvement of capabilities of people and equipment. Candidate will foster a lean transformation and sustainment culture while facilitating and educating lean manufacturing tools and techniques in a union environment.
- Demonstrated commitment to continuous improvement. Thinks independently, shows initiative, anticipates and prevents problems. Resourcefulness in accomplishing objectives and completing tasks.
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Demonstrated ability to lead and work well in a team environment. Ability to work effectively with multiple departments and employees at all levels in the organization.
- Demonstrated ability to handle large projects, including CapEx projects, and bring to conclusion. Excellent time management skills and ability to prioritize resources and project timelines.
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Competency in drawing interpretation, spreadsheet analysis, database research and presentation skills
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Aid in the selection of new machines, tooling, automation and processes required to meet productivity objectives.
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Ensure repeatable product quality and on-time delivery to our customer base. Assist the Quality Department in the development and implementation of corrective action.
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Work with Supply Chain to implement improvements while striving to attain a JIT delivery program. Continuously monitor production reporting and investigate root causes of missed shipments. Assist in the design of solutions and verify implementation of all systemic corrective actions for missing or late shipments. Control and monitor inventory and supply issues and assign corrective action and new methods for inventory tracking and control.
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Coordinate downtime, changeover, scrap and rework reporting. Investigate data and assign/implement corrective action. Create and maintain mechanism of providing visibility into operating performance.
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Work with other departments and units in the corporation to ensure cost reduction efforts are being addressed, implemented and sustained.
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Assists in the support of fellow CI engineers and will collaborate with them directly.
Continuous Improvement/Lean Enterprise:
- Work with the CI Manager to learn and deploy new and/or revised lean tools and methodologies. Focus on best practicing successful processes of other businesses/consultants and implement key learnings from internal testing.
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Identify opportunities for process consistency between sites and subsequently work with fellow CI engineers to develop and deploy standard work accordingly.
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Establish and utilize frameworks and systems, including tools such as visual management, problem solving, standard work and kaizen.
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Work with Engineering and Quality on design for manufacturability projects to improve both quality and production efficiencies.
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Adhere to and promote the HR Pledge.
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Cooperate and commit in a team environment to achieve goals and deliverables.
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Resolve difficult or complicated challenges using the problem-solving process.
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Actively embrace our core principles.
Supervisory Responsibilities
This position does not routinely supervise others. On occasion, however, this individual may be asked to fill in for absent production supervisory personnel. In this role, responsibilities include assigning and directing work, addressing complaints and resolving problems.
Competencies
Continuous improvement and manufacturing at Milbank are team endeavors; communication and teamwork are essential to who we are and how we succeed.
- Speak clearly and persuasively in positive or negative situations, demonstrate group presentation skills and ability to conduct meetings.
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Embrace and enjoy a diverse working environment, understanding the strengths the differences each of us brings to the team.
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Involve the hourly production team members in problem solving and process improvement.
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Foster and encourage an atmosphere of responsibility, quality and pride in all who function on the team
A Continuous Improvement Champion will:
- Be a leader, coach, mentor and subject matter expert for the lean manufacturing initiatives and their development, documentation and implementation.
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Develop cross-functional kaizen teams to address organization-wide continuous improvement initiatives. Lead kaizen events focused on efficiency improvements and cost reduction; report progress to management. Follow up on kaizen events and ensure proper metrics are installed to ensure sustainment of improvements.
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Have a fundamental understanding of supplier relations and performance, leadership, training, interpersonal relationships, improvement systems and professional ethics.
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Be able to plan, control, and assure product application, including design, manufacturing and construction.
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Have a thorough understanding of problem solving and lean manufacturing tools and techniques. This includes knowledge of management and planning tools, quality tools, preventive and corrective actions and how to overcome barriers to manufacturing improvements.
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Be able to acquire and analyze data using appropriate standard quantitative methods across a spectrum of business environments to facilitate process analysis and improvements.
Travel Required: Occasional. A valid driver’s license and ability to insure employee as a driver under the company auto policy is required.
Hours: Regular 40-hour workweek. Overtime as needed.
Working Conditions: Office and/or manufacturing plant floor setting. Required to sit, stand and frequently move about the facility. Required to use safety glasses and other PPE in specific areas. May occasionally be required to lift or move up to 50 lbs.
Education: Bachelor’s degree required, ideally related to continuous improvement or four to eight years of equivalent experience.
Experience | Skills:
Preferred: Four to eight years’ experience in lean manufacturing work. Demonstrated leadership skills with emphasis on cross-functional team development. Experience implementing continuous improvement and working knowledge of TPS philosophies utilizing the kaizen culture. Demonstrated ability to prioritize and manage kaizen teams while obtaining sustainable results. Proficient in blueprint reading and Microsoft Office tools including Excel, PowerPoint, etc. Experience managing KPI targets and critical metrics.
Strong mechanical aptitude with ability to learn and adapt to new processes are a plus. Experience with nationally recognized testing laboratories such as UL (Underwriters Laboratories). Background in sheet metal manufacturing, welding, paint systems and electrical and electronic component assembly a plus.
