Lean Process Engineer

Our client, a nationwide manufacturer of precision metal and steel products, has an immediate need for an experienced Lean Process Engineer, to join their winning team in Worcester.

Our candidate of choice will be responsible for responsible for driving continuous improvement and operational excellence throughout our manufacturing operations. This position works closely with Production, Engineering, Quality, Maintenance, and other departments to identify opportunities to improve productivity, quality, safety, delivery, and cost. You will spend significant time on the manufacturing floor observing processes, analyzing data, identifying root causes, developing practical solutions, and working with employees and management to implement sustainable improvements.

• Lead and support Lean manufacturing initiatives throughout the facility.
• Identify and eliminate waste, including excess motion, waiting, transportation, overproduction, inventory, defects, over-processing, and underutilized employee skills.
• Conduct and facilitate Kaizen events, improvement projects, and focused problem-solving activities.
• Apply Lean principles and tools such as 5S, Standard Work, Value Stream Mapping, Visual Management, Kanban, mistake-proofing (poka-yoke), and continuous flow.
• Develop and maintain standard work instructions and standardized operating procedures.
• Identify opportunities to improve manufacturing flow, reduce bottlenecks, and optimize production layouts.
• Analyze existing manufacturing processes (run rates) and develop improved methods, tooling, fixtures, layouts, and work procedures.
• Evaluate production processes to improve cycle time, machine utilization, labor efficiency, and overall equipment effectiveness.
• Perform time studies, process observations, capacity analyses, and line balancing.
• Develop process documentation, work instructions, process flow diagrams, and other engineering documentation.
• Work with Engineering and Production to improve manufacturability and process capability.
• Support the implementation and validation of new processes, equipment, tooling, and production methods.
• Lead structured root-cause investigations using methodologies such as 5 Whys, Fishbone/Ishikawa analysis, Pareto analysis, and other appropriate problem-solving tools.
• Work with cross-functional teams to develop corrective and preventive actions.
• Follow improvement projects through implementation to ensure solutions are effective and sustainable.
• Identify recurring process problems and develop permanent solutions rather than temporary fixes.
• Work directly with Production Supervisors, Leads, and employees to identify and resolve manufacturing issues.
• Provide engineering support for day-to-day production problems.
• Assist with troubleshooting equipment, tooling, process, and workflow issues.
• Support production scheduling and capacity planning as needed.
• Assist with training employees on new processes, standard work, and Lean practices.
• Promote employee involvement in continuous improvement activities.

• Bachelor’s degree in industrial engineering, Manufacturing Engineering, Mechanical Engineering, or a related field.
• Experience in a manufacturing environment.
• Strong understanding of Lean manufacturing and continuous improvement principles.
• Proficiency with Microsoft Office, particularly Excel.
• Experience in machining, CNC manufacturing, metal forming and stamping, or a similar discrete manufacturing environment.
• Experience with Value Stream Mapping, 5S, Kaizen, Standard Work, Kanban, and Visual Management.

• 401(k)
• 401(k) matching
• Health insurance
• Life insurance
• Paid time off
• Vision insurance