Continuous Improvement Engineer

Wells • Hillsboro, TX

2d

About The Position

The Continuous Improvement (CI) Engineer leads and facilitates continuous improvement initiatives across a precast concrete manufacturing operation. The role advances operational excellence by applying Lean Manufacturing, structured problem-solving, and data-driven decision-making to improve safety, quality, productivity, equipment reliability, and cost performance. The CI Engineer works with production, maintenance, quality, engineering, and leadership teams to identify opportunities, develop sustainable solutions, and strengthen long-term process stability.

The role participates in and coaches Tiered performance review meetings, analyzes operational metrics and Pareto data, and turns identified trends into structured improvement projects with measurable results. It leads through influence, coaching, and cross-functional collaboration and has no direct reports. The position reports to the SVP of Continuous Improvement and involves 10–15% travel between locations as needed.

The position leads the plant's CI program, manages improvement projects, facilitates root cause analysis and Lean activities, coaches employees and supervisors, and supports safety, compliance, and strategic operational goals. Performance is evaluated through measures including improvements in OEE and labor efficiency, completed and sustained projects, documented cost savings or avoidance, timely corrective-action closure, and reduced scrap, rework, and quality non-conformities.

The role requires regular walking in production areas and extended time on the manufacturing floor. It may involve climbing stairs or ladders, accessing elevated work areas, occasionally lifting up to 25 pounds, wearing PPE, and working amid industrial hazards and exposure to dust, noise, vibration, varying temperatures, and outdoor weather.

Requirements

• Strong understanding of Lean Manufacturing principles and continuous improvement methodologies.
• Ability to interpret operational data and identify meaningful trends and opportunities.
• Proficiency with Pareto analysis, root cause analysis, and corrective action processes.
• Strong analytical and problem-solving skills.
• Excellent communication and presentation abilities.
• Ability to influence and motivate employees at all levels of the organization.
• Strong project management and organizational skills, including the ability to manage multiple projects and meet deadlines.
• Proficiency with Microsoft Office applications, particularly Excel.
• Knowledge of manufacturing performance metrics and KPI management systems.
• Ability to walk production areas regularly and spend extended periods on the manufacturing floor.
• Ability to climb stairs and ladders and access elevated work areas as needed.
• Ability to occasionally lift up to 25 pounds.
• Ability to work in an industrial manufacturing environment and wear required PPE.

Nice To Haves

• Bachelor's degree in Engineering, Manufacturing, Operations Management, Industrial Technology, or a related field preferred; equivalent combinations of education, technical training, and relevant manufacturing or continuous improvement experience may be considered in lieu of a degree.
• Three to five years of manufacturing, operations, continuous improvement, or supervisory experience preferred.
• Experience with Power BI or AI.
• Experience in precast concrete or a similar heavy manufacturing environment.

Responsibilities

• Participate in and coach daily, weekly, and monthly Tiered (1–4) performance review meetings to review KPIs, identify trends, and prioritize improvement opportunities.
• Analyze Pareto charts and performance data to identify recurring losses, production constraints, quality defects, downtime events, and safety concerns.
• Assist in developing plant performance metrics and reporting systems.
• Lead the plant's continuous improvement program and promote operational excellence.
• Develop, prioritize, and manage improvement projects based on data-driven opportunities; establish objectives, timelines, success metrics, and accountability measures.
• Facilitate root cause analysis using 8-Step Problem-Solving, 5-Why, Fishbone Diagram, and Process Mapping methods.
• Lead cross-functional teams implementing corrective and preventive actions to eliminate waste and improve process performance.
• Coordinate work across departments to ensure projects are executed successfully and improvements are sustained.
• Monitor project progress and report results to plant leadership through visual management systems and performance dashboards.
• Track and verify improvement results in productivity, quality, safety, uptime, material utilization, and labor efficiency.
• Conduct process observations, workflow studies, and value stream mapping to identify inefficiencies and bottlenecks.
• Identify and reduce precast production losses, including mold/form changeovers, curing cycle time, batching and rebar fabrication flow, crane and yard logistics, and finishing or patching rework.
• Support Lean Manufacturing practices, including 5S, standard work, visual management, waste elimination, and continuous flow.
• Develop and maintain standard work procedures to sustain process improvements.
• Facilitate Kaizen events, improvement workshops, and employee engagement activities.
• Coach, guide, and train supervisors and employees in CI tools and methodologies.
• Collaborate with production supervisors, maintenance, quality, and engineering to identify and implement improvement opportunities.
• Partner with maintenance and engineering teams to improve reliability and process capability.
• Ensure improvement activities comply with safety policies, quality standards, and regulatory requirements.
• Apply CI tools to plant safety initiatives and incorporate safety into standard work.
• Support annual strategic initiatives and operational improvement goals established by plant leadership.

Benefits

• Medical, dental, and vision insurance
• Company-paid disability and life insurance
• Wellness incentives
• Paid holidays
• PTO
• Flexible spending accounts
• HSA options
• 401(k) with profit sharing
• Access to Nice Healthcare
• Employee assistance resources
• Pet insurance
• Additional voluntary coverage, including critical illness, accident, and hospital indemnity plans
• Health and family care leave

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level