Sr. MFG Engineer - Factory Efficiency

Senior Manufacturing Engineer – Factory Efficiency

The Senior Manufacturing Engineer – Factory Efficiency is the owner of factory performance improvement.

Your mission is to systematically increase throughput, reduce waste, stabilize processes, and unlock capacity across fabrication, powder coat, and assembly—without adding unnecessary headcount or capital.

This is a senior, hands‑on role for someone who can move comfortably between:

• Data analysis
• Shop‑floor observation
• Kaizen leadership
• Executive‑level conversations about capacity and margin

• Map value streams across fabrication, finishing, and assembly
• Identify and quantify constraints, bottlenecks, and flow disruptions
• Increase throughput using Lean principles, not heroics
• Support capacity modeling tied to revenue growth plans

• Lead structured Lean and Six Sigma initiatives (DMAIC, Kaizen)
• Establish standard work, visual management, and daily management systems
• Reduce variation and instability in critical processes
• Coach operators and supervisors on Lean thinking

• Analyze labor utilization and cycle times by operation
• Eliminate non‑value‑added work
• Improve ergonomics, material presentation, and line balance
• Partner with Costing and Finance to quantify savings

• Identify top drivers of scrap and rework
• Apply root cause analysis (5 Whys, Fishbone, SPC)
• Implement poka‑yoke and mistake‑proofing solutions
• Ensure fixes are documented and sustained

• Convert improvements into documented standard work
• Ensure standards are reflected in ERP routings and labor models
• Establish metrics to prevent regression
• Build repeatable CI playbooks—not one‑off wins

• Partner closely with Operations leadership
• Support Manufacturing Engineering Manager on factory‑wide initiatives
• Collaborate with Design and Manufacturing Engineering on DFM/DFA

These KPIs are what this role will be directly measured on. They combine process, efficiency, quality, and impact:

• Cycle Time Reduction – Average processing time per product across fabrication, powder coat, and assembly
• Throughput Increase – Number of complete units processed per shift/week/month
• Labor Efficiency / Utilization – % of available labor hours used effectively in value‑added work
• Scrap Rate – % of material scrapped vs total production
• Rework Rate – % of units requiring rework post‑production
• First Pass Yield – % of units passing inspection without modification
• Kaizen & CI Project Completion – Number of Lean / Six Sigma initiatives executed and completed
• Sustained Gains – % of improvements maintained after 90 days
• Work Cell Balance / Bottleneck Reduction – Variance in cycle times between operations and elimination of bottlenecks
• Labor Cost Savings / ROI – Actual savings from CI projects realized vs projected
• Operator Engagement / Adoption Rate – % of operators following standardized work and CI procedures
• Safety / Ergonomic Incidents – Reduction in ergonomic strain or unsafe handling incidents

These KPIs are tracked weekly and reported monthly to leadership. They tie directly into Engineering and Operations scorecards, ensuring CI is measured, recognized, and rewarded.

• Learn all factory processes, constraints, and current metrics
• Establish credibility and rapport with Operations and shop‑floor teams
• Identify top 3 high‑impact CI opportunities

• Lead at least one Kaizen or Six Sigma project
  
  Deliver measurable improvement in cycle time, labor efficiency, or yield
• Establish baseline metrics for ongoing tracking

• Demonstrate sustained improvement with documented standard work
• Quantify capacity or cost unlocked
• Present a 12‑month CI roadmap aligned to $20M growth

Required:

• 7–10+ years manufacturing or industrial engineering experience
• Proven success driving Lean and Six Sigma initiatives
• Experience in fabrication, sheet metal, or complex assembly environments
• Strong analytical and problem‑solving skills
• Ability to influence without formal…