Continuous Improvement Engineer

The Continuous Improvement Engineer is responsible for leading, developing, and maintaining (together with Production leadership), a production work environment characterized by a commitment to continuous improvement. The Continuous Improvement Engineer also must lead, co-implement, and maintain all processes, procedures, and system improvements in the production facilities; these processes and procedures should generate long-term benefits that involve the entire workforce. The continuous improvement methods implemented should include programs such as 5S, Lean Manufacturing, Kaizen, Six Sigma, 8-D, Problem Solving and Value Stream Analysis to drive out waste and improve productivity.

While based at a single facility, this role is a key position within a team responsible for the delivery of process innovation and continuous improvement initiatives across multi-jurisdictions. It will play an important role in helping to foster a culture of sustainable change through the creation and embedding of LEAN methodology, and the supporting framework, to deliver business transformation.

Essential Functions

Main duties

Continuous Improvement Program:

• Manages efforts to identify root causes of issues negatively impacting production objectives, including:
  1. Performs time studies and work flow analysis for production
  2. Provides work content data support to senior leadership for labor ROI
  3. Implements and maintains processes that sustain continuous improvement gains (i.e. Kamishibai)
  4. Reviews and assists with routing and/or other process flows created by production
  5. Leads or conducts studies in safety, cost, quality, productivity, flow, value stream mapping
• Leads and coordinates a wide variety of identified and approved initiatives and projects designed to improve processes and performance in all production facilities
  1. Establish, lead, and maintain a local Continuous Improvement Steering Committee
  2. Facilitate the selection, scope, and planning of specific improvement projects
  3. Identify goals for CI events and potential quantifiable savings
  4. Identify resource requirements and ROI estimates for improvement projects
  5. Lead Kaizen events and maintain reporting on events, event outcomes and action plans, and follow-up measurement results
  6. Participate actively to prove process concepts as well as implementation of improvement activities
  7. Monitor and maintain event schedules
  8. Follow up and audit event progress to ensure results are achieved and sustained
  9. Resolve implementation issues / create and manage implementation communication process
• Participate in new product development and/or product change initiatives
  1. Analyze manufacturing processes to identify and realize efficiency gains during new product introduction and/or product changes

Reporting:

• Establish appropriate measurement systems to identify opportunities and to quantify implemented improvements
• Lead teams to develop appropriate Key Performance Indicators (KPI’s) for their products, process, or function
• Participate with the local and global engineering teams on changes to and evolution of the Gibson Production System.
• Leads and executes all Visual Factory (VF) related objectives. Drives continuous progression in VF.
• Creates project proposals for Manufacturing Engineering using GEMBA data. 
• Verifies leadership standard work is up-to-date, executed and best practices are used.
• Works with EHS Specialist on ergonomic considerations.

Training:

• Train production employees on lean methodology and other continuous improvement tools and processes
• Train “change agent” employees, in all aspects of lean manufacturing, waste reduction, team effectiveness and continuous improvement
• Develop training materials and effectively deliver those materials in a team environment to ensure employees throughout the facilities are trained in CI concepts and philosophy
• Facilitate and mentor CI events and teams

Other duties

• Establishing and maintaining strong relationships with the Custom Shop leadership team so as to identify their needs and seek full range of business solutions
• Providing leadership in strengthening internal communications with staff at all levels throughout the organization; create and promote a positive and supportive work environment
• Employee can be asked to perform other duties that are reasonable within the area of expertise

Required Skills/Abilities

Skills and Competencies

• Must have a high level of self-motivation
• At ease and engaging as a Trainer and agent of change
• Strong written and verbal communication skills 
• Strong organizational skills
• Advanced Computer Skills (Excel, SQL, Minitab)
• Highly results oriented and focused on business priorities, with a successful record of accomplishments 
• Ability to effectively manage multiple assignments concurrently, including ability to assess and manage priorities
• Self-starter with analytical skills, able to identify problems and/or opportunities for improvement, assesses viable solutions, and develops and executes complex projects and comprehensive action plans

Education and Experience

• Bachelor’s Degree in Engineering required, IE or MFGE a plus; or 5+ years related experience in a manufacturing environment; or an equivalent combination of education and experience
• Minimum 5 years proven continuous improvement analytical experience from a similar role, including project management and business analysis
• Lean certification strongly desired, six-sigma certification a plus 
• Leadership/Trainer experience, in addition to industry experience, a plus

Travel Requirements

• Some local travel to and between the company’s Nashville manufacturing and distribution locations will be required (approximately 5 to 10%). 

Physical Demands

• Basic physical stances and actions (sitting, standing, walking)