Continuous Improvement Engineer

bp•US: Non-Office OH, OH

2d•$120,000 - $135,000•Hybrid

About The Position

The Continuous Improvement Engineer at TravelCenters of America uses process mapping, data analysis, root cause analysis, engineering methods, and Lean Six Sigma to identify and lead initiatives that improve operational performance. The role identifies high-impact opportunities, designs scalable solutions, leads enterprise-wide improvement efforts, and builds internal capability by coaching teams. It requires strategic ownership, decisive action, accountability, adaptability, and the ability to influence cross-functional teams while connecting improvements to customer experience and financial performance. The position leads complex, multifunctional projects and portfolios, supports solution launches and stabilization, and applies engineering tools such as simulation modeling, layout optimization, labor standards, time studies, resource modeling, and quality standards. It also supports automation, facilitates Value Stream Maps and Kaizen Events, analyzes customer feedback and operational data, reports progress to executives, and implements standardized corrective action systems. The role supports safety, risk, and compliance initiatives, including the “Believe in Zero” safety philosophy. The role is based in a professional office environment with hybrid office/remote work and travel to operational locations, including truck service shops. Travel of approximately 50–75% is expected. Site environments may include mechanical noise, diesel fumes, moving equipment, and substances typical of commercial vehicle maintenance. Appropriate PPE is provided and expected during site visits. The position involves frequent communication, strategic planning, and collaboration; site visits may include walking and standing, and lifting or moving up to 50 pounds may be required rarely. The posting lists a base salary range of $120,000–$135,000. Benefits described include medical, dental, vision, and life insurance, short- and long-term disability, a 401(k) match, retirement benefits that may include a pension for eligible employees, paid vacation and holidays, personal choice holidays, parental leave, tuition reimbursement, training and advancement opportunities, an annual bonus opportunity, a long-term incentive program, on-site meal discounts, and discounts on technology, travel, food, and fuel. Relocation assistance is not available for this role.

Requirements

At least 5 years of related experience in continuous improvement, process engineering, or operations in a similar industry.
Experience developing and managing Standard Work, Visual Management Systems, Management Accountability Systems, Plan-Do-Check-Act (PDCA), Value Stream Mapping, Kaizen Events, Lean Six Sigma projects, and 5S/Workplace Organization.
Intermediate understanding and experience in engineering and data analysis functions such as slotting, utilization, labor planning, layouts, and metrics.
Strong analytical, facilitation, and stakeholder management skills.
Proficiency in Microsoft Office Suite.
Experience with advanced engineering tools, data visualization platforms, and database programming; examples include Power BI, Minitab, AutoCAD, Labor Management Systems, SQL, and VBA.
Knowledge of truck service operations, data analytics, industrial engineering, and Lean Six Sigma methods.
Understanding of maintenance and repair solutions and automation types.
Familiarity with fleet management, vehicle maintenance operations, managed transportation networks, and equipment such as trucks, tractors, and trailers.
Valid driver’s license.
Ability to travel approximately 50–75%.
During site visits, light physical activity such as walking, standing, or navigating shop environments may be required; lifting or moving objects up to 50 pounds may be required rarely.
Visual acuity for reviewing operational data, facilities, and service documentation.

Nice To Haves

Bachelor’s degree in Engineering, Business Administration, or a related field; equivalent experience is considered.
Lean Six Sigma Black Belt certification.
PMP certification.

Responsibilities

Conduct process mapping, data analysis, and root cause analysis to identify inefficiencies and improvement opportunities.
Independently identify process gaps and systemic issues and design scalable solutions across sites or functions.
Develop, prioritize, and lead an enterprise-wide improvement plan delivering measurable results in safety, quality, delivery, cost, and employee development.
Partner with senior leadership to align improvement initiatives with strategic priorities and long-term goals.
Lead and facilitate complex multifunctional projects using Lean, Six Sigma, and other methodologies.
Manage project portfolios to support timely execution, stakeholder alignment, and sustained impact.
Support launch and stabilization phases and ensure solutions are embedded and continuously improved.
Apply engineering tools such as simulation modeling, layout optimization, labor standards, time studies, resource modeling, and quality standards.
Identify and support opportunities to implement automation in new and established processes.
Coach teams and develop internal capabilities in Lean Six Sigma, Continuous Improvement, and Quality Assurance.
Facilitate and execute Value Stream Maps and Kaizen Events, including ideation and chartering, pre-work, follow-up, and sustainment.
Apply process optimization, labor standards studies, layout optimization, data profiling and analysis, and resource modeling to improve Truck Service field and support center operations.
Analyze customer feedback and operational data to identify trends and opportunities to improve experience and performance.
Provide executive-level reporting on data and actions and make data-driven recommendations aligned with Truck Service strategy.
Implement and monitor standardized corrective action systems.
Support safety, risk, and compliance initiatives, prioritizing the “Believe in Zero” safety philosophy.
Perform other duties as assigned to support the continuous improvement mission.