Plant CI Engineer

Job Summary:

This Continuous Improvement position is accountable for identifying and completing projects and key initiatives at the plant level through the use of Six Sigma, Lean, and Project Management methodologies.  Working with plant leadership, managers, supervisors, engineering and quality teams to ensure the Continuous Improvement program is deployed effectively ensuring initialization of continuous improvement systems and tools are used and sustained to accelerate business improvement initiatives.  They will work closely with the Regional Continuous Improvement Manager to identify and drive Continuous Improvement initiatives that result in performance and customer satisfaction improvement. 

Position Responsibilities:

• Develop continuous improvement – lean manufacturing and Six Sigma methodologies in the day to day operations
• Facilitate process improvement teams and provide counsel and assistance to the project team leaders with respect to facilitation techniques, quality systems, continual improvement, people development and safety improvement.
• Assist in the facilitation of key programs
• Lead workshops resulting in tangible key performance indicator improvements
• Deploy the appropriate People / Safety / Quality / Cost / Delivery / Productivity metrics and management routines at all levels of the organization
• Contribute to strategic planning at the plant level
• Act as a change agent (leader) to instill a Problem Solving and Continuous Improvement culture on site and in related areas of the company
• Ensure through audits that tools are appropriately and effectively used
• Develop and maintain the site’s annual 12-months rolling lean implementation plan based on the strategic plan
• Develop, manage, and report progress of the lean deployment plan with site management (based on current and future state Value Stream Maps, site performance improvement targets, and Group / Business standards, policies and best practices)
• Support site management in its strategic planning process and its implementation by taking ownership of relevant projects, that are a subset of the core responsibilities, and by taking a leading role in other key programs
• Contribute to the Continuous Improvement network development.  Ensure 2-way communication throughout the continuous improvement organization.  This includes communicating project status and coordinating activities between the Regional Continuous Improvement Manager and other Continuous Improvement Managers/Leaders.  This includes capturing project lessons learned and submitting activity reports. 
• Understand all environmental policies and significant environmental impact of job activities
• Understand all safety policies and significant safety impact of job activities
• Assist leadership in the planning, development, coordination, support, and execution of high impact (immediate and long term) improvement plans for effective and sustainable cost saving initiatives while making sure lean manufacturing and Six Sigma initiatives are aligned with customer focused metrics.  
• Work with local financial representative to validate project justification and success when necessary.
• Promote the use of metrics and data to drive project focus.

Education/Experience

• Bachelor’s Degree required; Engineering preferred.
• Minimum 5 years of manufacturing or similar experience.
• Six Sigma Green Belt certification preferred but not required
• Experience in facilitating Kaizen workshops with demonstrated high impact results.
• Demonstrate formal training and experience with Value Stream Management tools, Kaizen methods, and strategy deployment as well as demonstrated strengths in strategic business assessment and business planning.
• A demonstrated understanding of Lean principles such as Value Stream Mapping, Just-In-Time, Demand Flow, Single Piece Flow, Continuous Improvement Process, Kaizen, SPC, Six Sigma and Communication Tools, and Statistical Problem Solving
• Thorough understanding of lean tools such as standardized work, 5S, SMED, TPM, Kanban, MIFA, Error Proofing and etc.
• Understanding and experience with problem solving methods like 8D PPS or A3 
• Thorough understanding of the DMAIC methodology Analytical skills including key statistical methods commonly used in Six Sigma
• Has high energy and experience inspiring and motivating cross-functional teams.
• Previous Program/Project management with demonstrated project results from concept thru completion
• Previous operations management experience preferred.

Skills/Abilities

• Self-starter with the ability to develop/implement strategies in line with the company’s business vision.
• Strong leadership skills with the proven ability to set a vision, manage change, develop personnel and strategically implement continuous improvement.
• Previous Program/Project management skills from concept, planning thru turnkey completion
• Strong interpersonal relationship skills.
• Knowledge of FDA cGMP’s
• Working knowledge of Lean Six Sigma preferred
• Experience in Pharmaceutical industry preferred
• Experience in Printing industry – folding cartons, inserts
• Proven track record of improving quality, efficiency, and workflow in a production environment
• Personal/Professional development history
• Strong communication skills – written and verbal
• Excellent computer skills, knowledge of MS office, Access, Project

Unique Requirements:

• Leadership skills: Lead by example; take charge; good judgment; decisiveness; provide direction; coach/develop
• Analytical skills:  Situation Appraisal; Problem Analysis; Decision Analysis; Potential Problem/Opportunity Analysis; Statistical Analysis
• Change Management: Over come barriers/obstacles; exhibit flexibility /adaptability
• Quality Awareness : Quality System ISO ; Statistical Process Control; Continuous Improvement; cGMPs
• Health, Safety, Environment:  Regulatory Compliance
• Manufacturing:  Process Improvement; Material flow and Process Flow; Performance Measurement; Lean Manufacturing Concepts
• Operations:  Component Requirements; Planning; Scheduling
• Pharmaceutical Packaging Safety: OSHA
• Financial Management:  Business Plan; Facility Financials
• Diversity:  Multi-cultural work environment

Work Environment:

• The performance of this position will require exposure to the manufacturing areas where the use of personal protective equipment such as hearing protection may be required.  Requires the removal of personal items such as jewelry, rings, bracelets, watches, necklaces, and earrings. 
• Travel requirements 25% for meetings, training, and etc.