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Continuous Improvement Engineer

4 months ago

Asheboro, United States Kennametal Full time

Summary


The Plant Continuous Improvement Engineer is responsible for implementing continuous improvement initiatives, analyzing existing processes, identifying areas for improvement, and leading kaizen activities to optimize operations and increase efficiency. They will collaborate with plant management to drive alignment, gain support, train personnel and implement improvement initiatives.

Key Job Responsibilities

Lean COMPETENCES

Implement Lean methodologies: The Continuous Improvement Engineer applies Lean principles, tools, and techniques such as 5S, Kaizen, Standard Work, and Muda hunting to identify and eliminate waste in processes. They work with cross-functional teams to implement Lean projects and initiatives that improve productivity, quality, and overall performance. Develop the Lean competences of the operation through training & coaching.

Lean STRATEGIES

Help to define the Lean strategy of the operation in accordance with Plant / Site priorities and ensure deployment of Kennametal Operation/Production System within the operation area.

Lean GENBA ACTIVITIES

Help Plant / Production Manager to manage continuous improvement and to continuously detect abnormalities vs Lean standards and react. Process analysis and optimization: by analyzing existing processes at the site to identify areas of improvement. Able to conduct time studies, collect data, and use Lean tools to identify bottlenecks, inefficiencies, and opportunities for improvement. He/she works with site personnel to streamline workflows, reduce cycle times, and enhance process efficiency. Training and coaching: The Site Continuous Improvement Engineer provides training and coaching to site personnel on Lean principles and methodologies. He/she educates employees on Lean concepts, tools, and techniques to foster a culture of continuous improvement. He/she may conduct workshops, training sessions, and provide hands-on support to ensure employees understand and apply Lean principles effectively. Kaizen workshop management: The Continuous Improvement Engineer leads and manages Lean projects at the site. He/she collaborates with cross-functional teams to define project goals, develop project plans, allocate resources, and ensure timely implementation. He/she monitors project progress, track key performance indicators (KPIs), and communicate results to site management.

Lean RESULTS

Data analysis and reporting: The Site Continuous Improvement Engineer collects and analyzes data related to site performance, process metrics, and key performance indicators. To prepare reports, charts, and visualizations to communicate performance trends and improvement opportunities. Providing regular updates to site management and share insights to drive decision-making. Promote a culture of continuous improvement at the site and engage site personnel at all levels, encouraging them to contribute ideas, provide feedback, and participate in improvement initiatives. He/she facilitates improvement events, foster a mindset of innovation, and champion Lean practices within the site. Deploy lean standards & best practices within the operation and regional/global OpEX team. Highlight the main responsibilities:

Lean COMPETENCES

Develop his/her own competences and skills in tools and methodologies useful for the operation area. Train operation team members to lean tools, standards & methodologies & ensure that lean standards are known and applied properly. Participant regional/global kaizen week, share good practice kaizen workshop. Participant lean tool improvement working group, contribute the lean standard/tool improvement.

Lean STRATEGIES

Ensure that lean rules are considered in new projects at an appropriate phase. Help the production Manager to keep a continuous improvement mindset, behavior & policy, whatever the operational situation. Organize annual VSM going through the production and propose the yearly workshops list. Help to define the lean strategy of the production and prepare the operation budget concerning lean targets & budget. Manage the deployment of KPS within the production: manage production self-assessment with production team members and improvement action plan. Deploy lean standards & best practices within the production team.

Lean GENBA ACTIVITIES

Coach operation team members on application of lean tools and methodologies through On Job Training. Support workshop pilots, lead workshops and implement improvement proposals. Permanently help plant/production Manager to detect and react to non-conformances against lean standards. Manage the maintenance of lean tools through appropriate audits (like KPS, 5S, Kanban audits, leader standard work) : audit organization, performance & follow up. Prepare & organize the weekly production lean committee (incl. agenda proposal) lead by the Production Manager, review kaizen workshop progress on genba and write the minute. Check regularly in-depth the proper deployment of lean in the operation area. Support kaizen workshop pilots on methodology and results achievement. Lead himself/herself permanently workshops and implement improvement proposals. Permanently promote the lean principles.

Lean RESULTS

Ensure a lean reporting, KOS metrics correct. Quarterly lean mission report, share with site management team kaizen workshop status and saving achievements. (last quarter completed workshop, next quarter planned workshop, year to day saving summary, etc.)

Requirements

At least 1 year Production or logistic supervisor, process engineering related experience. 6Sigma greenbelt is plus.  Knowledge and practice experience of the following tools: Strong communication, teaching and coaching skills. 5S & Zoning. Standard work and cycle time measurement. Muda Hunting SMED TPM