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:

• Performs time studies and work flow analysis for production

• Provides work content data support to senior leadership for labor ROI

• Implements and maintains processes that sustain continuous improvement gains (i.e. Kamishibai)

• Reviews and assists with routing and/or other process flows created by production

• 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

• Establish, lead, and maintain a local Continuous Improvement Steering Committee

• Facilitate the selection, scope, and planning of specific improvement projects

• Identify goals for CI events and potential quantifiable savings

• Identify resource requirements and ROI estimates for improvement projects

• Lead Kaizen events and maintain reporting on events, event outcomes and action plans, and follow-up measurement results

• Participate actively to prove process concepts as well as implementation of improvement activities

• Monitor and maintain event schedules

• Follow up and audit event progress to ensure results are achieved and sustained

• Resolve implementation issues / create and manage implementation communication process

• Participate in new product development and/or product change initiatives

• 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)