Continuous Improvement Engineer

Requirements

• 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
• (Desirable) Lean certification (Lean Bronze, Lean Practitioner) or Six Sigma Green Belt
• (Desirable) Experience in a regulated manufacturing environment (AS9100, ISO 9001, or equivalent)
• (Desirable) Exposure to additive post-processing, quality inspection (CMM, CT scanning, optical), or materials qualification workflows
• (Desirable) Familiarity with ERP/MES systems and build data traceability in an AM context
• (Desirable) Experience leading kaizen events as a facilitator, not just a participant

• The 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 under‑utilized 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
• Process Stabilization & Build Quality
• 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
• Metrics & Performance Management
• 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
• Cross‑Functional Collaboration
• 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