Project and Continuous Improvement Engineer

Location: Forest City

** Overview*
* This position is responsible for leading project engineering, environmental and safety compliance support, and plant-wide continuous improvement strategy. The role combines hands-on project execution with Lean/Six Sigma leadership to improve OEE, product quality, waste reduction, energy conservation, safety, equipment performance, and operating costs.

Qualified candidates must be self-starters with strong leadership, communication, problem-solving, and organizational skills. The position works closely with Operations, Maintenance, Engineering, Environmental, Quality, Lean/CI, supervisors, hourly associates, corporate resources, and outside contractors to identify opportunities, develop solutions, manage projects, and sustain improvements across the facility.

** Responsibilities*
* Project Engineering

+ Manage environmental, facility, equipment, and process improvement projects from concept through completion, including scope, justification, cost estimates, schedules, budgets, implementation, startup, and closeout.

+ Execute capital and expense projects on time and within budget, including assisting with CER preparation and project requirement definition.

+ Coordinate project activities involving maintenance resources, salaried and hourly employees, contractors, plant operations, and corporate staff.

+ Work from concepts to create equipment designs or process improvements.

+ Develop and maintain plant site drawings, equipment drawings, process flow diagrams, electrical prints, and other technical documentation.

+ Develop new concepts, techniques, equipment upgrades, and process-control improvements to increase efficiency, quality, throughput, and equipment performance.

+ Determine necessary actions and delegate resources effectively to increase safety, quality, OEE, efficiency, and cost performance.

+ Perform FMEA, Root Cause Failure Analysis, troubleshooting, and other structured problem-solving methods to resolve equipment, process, and quality issues.

Continuous Improvement & Lean/Six Sigma

+ Develop and implement a plant-wide Lean/Six Sigma and continuous improvement strategy with goals, objectives, timetables, action plans, and hourly and salaried leader engagement strategies.

+ Lead and support continuous improvement activities aligned with business goals, including safety, OEE improvement, product quality, waste reduction, energy conservation, and operating-cost reduction.

+ Coordinate plant-level Lean/Six Sigma initiatives with Element Resources continuous improvement initiatives to optimize resources and minimize redundant efforts.

+ Conduct daily plant walk-throughs and inspections with functional leaders, supervisors, and hourly associates to identify improvement opportunities and develop justifications for potential cost savings.

+ Conduct time and motion studies, value stream mapping, process charting, production standard validation, and workflow analysis to troubleshoot and streamline plant processes.

+ Work with Production, Lean/CI, Maintenance, Engineering, Environmental, and Quality teams to plan and execute Kaizen events and other improvement activities.

+ Train and mentor leadership, engineering staff, supervisors, and hourly associates in Lean principles, 5S, Six Sigma methods, standard work, change management, and continuous improvement tools.

Safety, Environmental & Compliance

+ Assist in development and implementation of safety protocols, environmental compliance systems, and manufacturing strategies.

+ Work with plant operations and Environmental personnel to implement systems that ensure compliance with required Environmental and Safety regulations.

+ Participate in training and development programs related to environmental, health, and safety issues.

+ Support development, revision, training, and adherence to SOPs, work instructions, standard operating procedures, and safety rules for new and existing equipment and processes.

Leadership, Communication & Documentation

+ Provide support and, at times, direct supervision of hourly and/or salaried employees and outside contractors.

+ Lead and/or participate in training of supervisory and hourly staff on SOPs, Lean/CI methods,…