Continuous Improvement Engineer

This job operates in a manufacturing / assembly environment. This role routinely uses standard construction-type equipment such as ladders and hoists as well as office equipment such as machines. Some of the work will require exposure to loud noises or fumes in the facility.

The Continuous Improvement Engineer is responsible for driving process optimization and operational excellence within Stellar Energy’s manufacturing and quality processes. Reporting to the Director of Quality Manufacturing, this role focuses on implementing and leading continuous improvement initiatives using advanced problem-solving methodologies such as 5Y2H, A3, 8D, and Fishbone diagrams. The position involves leading Kaizen activities, developing charters to support improvement projects, and enhancing the Quality Management System (QMS) in alignment with ISO 9001 standards. The Continuous Improvement Engineer collaborates with cross-functional teams to identify inefficiencies, reduce waste, and improve product quality and operational performance.

• Train and mentor employees on Lean, Six Sigma, and other continuous improvement methodologies to foster a culture of operational excellence.
• Act as a liaison between manufacturing, engineering, and quality teams to ensure seamless integration of improvement initiatives with organizational objectives.
• Analyze operational and quality data using statistical tools (e.g., Minitab, Power BI, or Excel) to monitor performance metrics, identify trends, and propose data-driven solutions.
• Ensure all continuous improvement activities comply with safety, environmental, and regulatory requirements, supporting Stellar Energy’s sustainability goals.
• Monitor and report on key performance indicators (KPIs) related to process efficiency, quality, and cost savings, providing regular updates to the Director of Quality Manufacturing.
• Plan, organize, and lead Kaizen events to drive rapid process improvements, engaging cross-functional teams to implement sustainable solutions.
• Develop and manage project charters to define objectives, scope, timelines, and deliverables for continuous improvement activities, ensuring alignment with organizational goals.
• Support the implementation of automation and technology solutions to streamline processes and improve operational efficiency.
• Lead and facilitate continuous improvement initiatives using structured problem-solving tools, including 5Y2H, A3, 8D, and Fishbone diagrams, to identify root causes of process inefficiencies and quality issues.
• Collaborate with the Quality Control (QC) and Quality Assurance (QA) teams to integrate continuous improvement methodologies into daily operations, reducing variability and enhancing product reliability.
• Conduct process audits and gap analyses to identify opportunities for improvement in manufacturing and quality processes, recommending actionable solutions.
• Support the development, implementation, and continuous improvement of the Quality Management System (QMS) to ensure compliance with ISO 9001 standards.

Must be authorized to work in USA.

This is largely a sedentary role; however, some filing is required. This would require the ability to lift files, open filing cabinets and bend or stand as necessary. The employee must occasionally lift or move up to 25 pounds. The employee must also be able to climb a ladder.

Work Authorization

Anticipated travel is minimal, approximately 10%, primarily for training or supplier visits. Occasional local day travel may be required.

• Experience leading Kaizen events and developing project charters for process improvement initiatives.
• Proficiency in data analysis tools (e.g., Minitab, Power BI, Excel) and statistical process control (SPC).
• Strong project management and facilitation skills for leading Kaizen events and improvement projects.
• Strong organizational skills with a focus on detail and accuracy in project execution.
• Excellent communication and leadership skills to engage and influence cross-functional teams.
• Lean Six Sigma Green Belt certification or higher is preferred.
• Minimum of 3 years of experience in continuous improvement, process engineering, or a quality-related role within a manufacturing environment.
• Demonstrated expertise in problem-solving methodologies such as 5Y2H, A3, 8D, and Fishbone diagrams.
• Proficiency in statistical analysis tools (e.g., Minitab, Power BI, or Excel) and Lean/Six Sigma methodologies.
• In-depth knowledge of ISO 9001 standards and Quality Management Systems (QMS).
• Expertise in advanced problem-solving methodologies (5Y2H, A3, 8D, Fishbone).
• Bachelor’s degree in industrial engineering, Manufacturing Engineering, or a related field from an accredited university.
• Strong understanding of ISO 9001 standards and experience supporting or managing QMS processes.