Continuous Improvement Engineer

Position Summary

Continuous Improvement Engineer – Additive Manufacturing drives systematic waste elimination and process excellence across the AM value stream. Using Lean methodologies, this role partners with operations, quality, and design engineering to identify root causes, reduce cycle time and scrap, stabilize build processes, and build a culture of continuous improvement on the production floor. The ideal candidate combines hands‑on knowledge of additive manufacturing processes with structured problem‑solving discipline and the communication skills to lead cross‑functional kaizen activity.

• Lead value stream mapping (VSM) exercises across AM production to identify and prioritize waste — including overproduction, wait time, transport, motion, over‑processing, defects, and underutilized talent.
• Facilitate kaizen events and rapid improvement workshops targeting throughput, first‑pass yield, and setup/changeover time reduction.
• Develop and maintain standard work documentation (SOPs, work instructions, visual aids) that lock in gains and support operator consistency.
• Drive 5S implementation and sustainment across AM work cells; establish audit rhythms and visual management systems.
• Own CI project pipeline — intake, prioritization, chartering, execution, and results verification — with clear ROI tracking.

• Analyze build failure data, non‑conformances, and scrap trends to identify systemic issues; lead structured root cause analysis (RCA) using A3, 5‑Why, and fishbone tools.
• Collaborate with AM process engineers to establish and maintain process parameter baselines, ensuring builds run to proven recipes with minimal variation.
• Support post‑process improvement initiatives including heat treatment, finishing, inspection, and part qualification workflows.
• Champion mistake‑proofing (poka‑yoke) solutions that reduce operator error and build‑to‑build variation.

• Define, track, and report key CI metrics: OEE, first‑pass yield, scrap rate, cycle time, on‑time delivery, and cost per part.
• Develop and maintain visual performance boards (physical or digital) at the cell level to enable daily accountability conversations.
• Establish baseline measurements before improvement initiatives and validate sustained results post‑implementation.
• Present project status, results, and CI pipeline health to operations leadership on a regular cadence.

• Partner with quality engineers to integrate CI work with the quality management system (QMS), CAPA processes, and corrective action tracking.
• Engage with design and applications engineering to provide DfAM (Design for Additive Manufacturing) feedback that reduces downstream production complexity.
• Mentor operators and technicians on Lean fundamentals, standard work adherence, and problem‑solving tools; build floor‑level CI capability over time.
• Coordinate with supply chain and procurement on supplier quality issues that create variation or waste in the AM process.

• 3–8 years of experience in manufacturing engineering, industrial engineering, or a CI/Lean role in a production environment.
• Demonstrated hands‑on experience applying Lean tools: 5S, standard work, VSM, kaizen facilitation, visual management, and root cause analysis.
• Familiarity with additive manufacturing processes (FDM, SLA, SLS, DMLS, or equivalent) — either through direct work experience or formal training.
• Proficiency in data analysis using Excel, Minitab, or similar tools; ability to build and interpret control charts, Pareto analyses, and run charts.
• Strong written and verbal communication skills; able to present CI project results clearly to both technical and non‑technical audiences.
• Bachelor's degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or a related technical field — or equivalent practical experience.

• Lean certification (Lean Bronze, Lean Practitioner) or Six Sigma Green Belt.
• Experience in a regulated manufacturing environment (AS9100, ISO 9001, or equivalent).
• Exposure to additive post‑processing, quality inspection…