Senior Process Improvement Engineer Door Line

Senior Process Improvement Engineer – Door Line, Louisville, KY

Drive Operational Excellence. Lead Continuous Improvement. Shape the Future of Manufacturing. Are you energized by solving complex manufacturing challenges, improving processes, and leading continuous improvement initiatives? In this highly visible role, you’ll serve as the technical leader for a manufacturing value stream, partnering with Operations, Quality, Maintenance, and Advanced Manufacturing teams to improve safety, quality, delivery, and cost performance.

• Equipment Reliability & Performance: Own manufacturing equipment and tooling within your production area following Advanced Manufacturing Engineering (AME) handoff. Serve as the primary technical expert for troubleshooting and resolving manufacturing process issues. Drive improvements in Overall Equipment Effectiveness (OEE), uptime, and productivity. Develop and audit preventive maintenance programs to maximize equipment reliability. Partner closely with Maintenance and Operations teams to prioritize repairs and improvement activities.
  
  Manage equipment calibration, specialized tooling, and process documentation. Provide technical input on future equipment purchases, upgrades, and manufacturing standards.
• Process Improvement & Manufacturing Excellence: Ensure manufacturing processes comply with established Manufacturing Control Plans (MCP) and production standards. Analyze production data, identify root causes, and implement corrective actions to improve performance. Partner with Quality and Operations teams to improve OEE, yield, scrap reduction, and customer quality metrics. Lead cross‑functional problem‑solving efforts to quickly resolve production issues. Develop and maintain standard work, job instructions, and process documentation.
  
  Utilize data‑driven decision making to optimize manufacturing performance.
• Continuous Improvement: Lead root cause investigations and implement sustainable corrective actions. Promote and teach Appliance Performance System (APS) principles and Lean manufacturing methodologies. Facilitate Kaizen events and continuous improvement initiatives. Identify opportunities to eliminate waste, improve efficiency, and increase productivity. Implement mistake‑proofing (Poka‑Yoke) solutions and workstation improvements. Support line balancing activities and workforce optimization using Lean tools and methodologies. Share best practices across manufacturing operations to drive enterprise‑wide improvements.
• Safety & Compliance: Identify and implement safety improvements within the manufacturing area. Support corrective actions resulting from safety audits, near misses, ergonomic assessments, and incident investigations. Develop and maintain Lockout/Tagout procedures for manufacturing equipment. Partner with Operations leaders to foster a strong safety culture.
• New Product Introductions (NPI): Collaborate with Advanced Manufacturing Engineering on new equipment installations and qualifications. Provide critical plant feedback during product development and launch activities. Evaluate new product designs for manufacturability and production readiness. Participate in prototype builds, product trials, and launch activities. Support capacity planning, workstation design, standard work development, and process documentation. Work with suppliers, OEMs, and engineering teams to ensure successful equipment integration and knowledge transfer.

Minimum Qualifications:

• Bachelor’s degree in a technical discipline OR equivalent experience.
• Minimum of 5 years’ experience in Manufacturing Engineering, Operations, or Quality support roles OR equivalent military experience.
• Experience with troubleshooting robotic manufacturing equipment.
• Demonstrated experience in troubleshooting high‑volume manufacturing equipment.
• Proven ability to influence and drive change.
• Experience in a high‑volume manufacturing environment.
• Solid verbal and written communication skills coupled with strong interpersonal skills.
• Advanced computer skills – high proficiency in Microsoft products (especially Excel) and ability to grasp new systems quickly.
• Strong…