Continuous Improvement Engineer

Winchester Interconnect•Garden Grove, CA

About The Position

As our Continuous Improvement Engineer, you will be the catalyst for operational excellence across our Engineered Cables Division. You will lead the identification, development, and implementation of Lean Manufacturing and Six Sigma initiatives to drive measurable improvements in safety, quality, delivery, cost, and efficiency throughout our high-mix, low-volume aerospace and defense manufacturing operations. This hands-on role requires both technical expertise and strong leadership skills to facilitate cross-functional improvement events, mentor team members in continuous improvement methodologies, and create a culture where innovation and problem-solving are embedded in daily operations. You will use data-driven analysis, process mapping, root cause analysis, and proven improvement tools to eliminate waste, optimize workflows, and deliver sustainable results that directly impact our bottom line and customer satisfaction. Working closely with Production, Engineering, Quality, and Supply Chain teams, you will champion Winchester's commitment to operational excellence while ensuring compliance with AS9100 quality management system requirements and customer specifications for our aerospace and defense customers. This position reports to the VP, EC and plays a critical role in supporting our strategic growth goals through disciplined, systematic process improvement.

Requirements

Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or related technical discipline required.
3-5 years of experience in continuous improvement, process improvement, or industrial engineering roles in a manufacturing environment.
Lean Six Sigma certification required: Green Belt minimum, Black Belt strongly preferred.
Demonstrated hands-on experience implementing Lean Manufacturing principles including 5S, Kaizen, Value Stream Mapping (VSM), Standard Work, Visual Management, and Pull Systems.
Proven experience leading cross-functional improvement events and projects from concept through implementation and sustainment.
Strong knowledge of Six Sigma methodologies including DMAIC (Define, Measure, Analyze, Improve, Control), root cause analysis (RCA), and statistical analysis tools.
Experience with AS9100 and ISO9001 quality management systems preferred.
Proficiency with data analysis tools including Microsoft Excel, Minitab, or similar statistical software.
Experience with ERP systems (Syspro experience a plus) and manufacturing execution systems.
Strong project management skills with ability to manage multiple concurrent improvement initiatives.
Excellent analytical and problem-solving skills with ability to collect, analyze, and interpret complex data.
Outstanding communication and presentation skills with ability to influence and engage stakeholders at all levels of the company.
Proven ability to train, coach, and mentor employees on continuous improvement tools and methodologies.
Self-motivated with ability to work independently and drive initiatives without direct supervision.
Collaborative team player who builds trust and credibility across functional boundaries.
Detail-oriented with strong organizational and time management skills.
Ability to work in a fast-paced manufacturing environment and adapt to changing priorities.
Must be a U.S. Citizen or Permanent Resident (Green Card Holder) to comply with ITAR regulations.

Nice To Haves

Aerospace, defense, or high-reliability manufacturing (medical device, space) experience strongly preferred.
Experience in high-mix, low-volume manufacturing operations a plus.
Familiarity with ITAR regulations and aerospace/defense manufacturing requirements a plus.
APICS certification (CPIM, CSCP) or Project Management Professional (PMP) certification a plus.

Responsibilities

Lead and facilitate Kaizen events, rapid improvement workshops, and value stream mapping (VSM) activities to identify and eliminate waste in processes, materials, motion, waiting, transportation, inventory, and defects.
Conduct time studies, process observations, and workflow analysis to identify non-value-added activities and develop solutions to improve productivity, cycle time, and throughput.
Implement Lean Manufacturing principles including 5S, visual factory management, standard work, single-piece flow, pull systems, and cellular manufacturing.
Design and optimize factory layouts, workstation configurations, and material flow to reduce travel distance, minimize handling, and improve ergonomics.
Develop and implement poka-yoke (mistake-proofing) devices and error-prevention systems to enhance quality and reduce defects at the source.
Create visual management systems including production boards, KPI dashboards, Andon systems, and performance tracking displays.
Lead Six Sigma projects using DMAIC methodology to solve complex quality, efficiency, and cost problems with measurable, sustainable results.
Conduct root cause analysis (RCA) using tools such as 5 Whys, Fishbone Diagrams, Pareto Analysis, and FMEA to identify and address systemic issues.
Perform statistical analysis including hypothesis testing, regression analysis, control charts (SPC), process capability studies (Cp, Cpk), and correlation analysis.
Establish baseline metrics, set improvement targets, and measure results to validate effectiveness of improvement initiatives.
Use A3 problem-solving methodology to document problems, analyze root causes, develop countermeasures, and standardize solutions.
Develop and execute comprehensive continuous improvement roadmap aligned with strategic business objectives including cost reduction, quality enhancement, on-time delivery improvement, and capacity expansion.
Establish and track key performance indicators (KPIs) including Overall Equipment Effectiveness (OEE), First Pass Yield (FPY), Scrap Rate, Cycle Time, Lead Time, Inventory Turns, and Labor Productivity.
Partner with leadership team to identify improvement priorities based on business impact, customer requirements, and strategic growth initiatives.
Lead cross-functional improvement teams including members from Production, Engineering, Quality, Supply Chain, and Maintenance.
Facilitate structured problem-solving sessions, brainstorming workshops, and improvement meetings to drive engagement and results.
Design and deliver training programs on Lean Manufacturing, Six Sigma, and continuous improvement tools for employees at all levels.
Coach and mentor team members in applying improvement methodologies to daily work, developing their problem-solving capabilities and continuous improvement mindset.
Develop training materials, standard operating procedures (SOPs), work instructions, and visual aids to support knowledge transfer.
Create and sustain a culture of continuous improvement where all employees are engaged in identifying and implementing improvements.
Ensure all continuous improvement activities support and enhance AS9100 and ISO9001 quality management system compliance.
Partner with Quality Assurance to align improvement initiatives with quality objectives, customer requirements, and regulatory standards.
Support internal and external audits by documenting process improvements and maintaining evidence of continuous improvement.
Manage multiple concurrent improvement projects from initiation through closure, ensuring on-time delivery within budget and scope.
Develop detailed project plans including timelines, resource requirements, budget estimates, risk assessments, and success metrics.
Conduct post-implementation reviews to validate results, capture lessons learned and identify opportunities for further improvement.
Generate regular reports and dashboards showing continuous improvement project status, financial benefits, and key metrics trends.
Calculate and report financial impact of improvement initiatives including cost savings, cost avoidance, productivity gains, and quality improvements.
Benchmark industry best practices in aerospace and defense manufacturing and identify opportunities to adopt proven methodologies.
Support New Product Introduction (NPI) by partnering with Engineering to ensure Design for Manufacturability (DFM) principles are applied.
Comply with all company policies and procedures.
Perform other duties as assigned.