Continuous Improvement Engineer

Carolina Foods Inc. • Pineville, NC

9d • $100,000 - $100,000 • Onsite

About The Position

The Continuous Improvement Engineer leads hands-on plant-floor improvements to reduce losses, improve production performance, and build reliable processes. The role focuses on OEE performance and quality, ingredient and packaging waste, labor utilization, and changeover efficiency. Working with Production, Maintenance, Reliability, Sanitation, and Quality, the engineer identifies major losses, leads root cause analysis, implements lasting improvements, and verifies sustained results. The role also serves as the plant's technical liaison for automated baking line startup and commissioning, translating improvements into standard work, training, and daily operating routines.

The position supports startup and commissioning of highly automated baking lines, equipment testing and debugging, ramp-up, TPM, troubleshooting, material-handling flow design, SOP development and training, and the site's Management Operating Structure. It requires active attention to employee safety, food safety, product quality, GMPs, and housekeeping. The role is onsite and plant-floor based in a high-volume industrial bakery, with computer work for analysis, documentation, and coordination. Conditions may include heat, noise, moving equipment, and material-handling traffic. Minimal travel is expected; work may involve nonstandard shifts, weekends, and holidays, especially during startups and critical project milestones.

Requirements

• Bachelor's degree in engineering, food science, operations management, or a related field, or equivalent relevant experience.
• Three to five years of hands-on manufacturing experience applying continuous improvement or Lean methods, with demonstrated, measurable results.
• Hands-on experience starting up and commissioning automated production equipment, including FAT/SAT, debugging, and ramp-up to rated performance.
• Demonstrated root cause analysis and problem-solving skills, with working knowledge of GMPs and food safety requirements.
• Strong verbal and written communication skills, including facilitating meetings and training employees.
• Proficiency with Microsoft Office and production data analysis.
• Sound independent judgment, strong organization, and ability to manage several projects and competing priorities in a results-driven environment.
• Flexibility to work nonstandard shifts, weekends, and holidays, particularly during equipment startups and critical project milestones.

Nice To Haves

• Experience in food, baking, or other process manufacturing.
• Lean Six Sigma Green Belt certification or higher, and hands-on experience with TPM, SMED, and OEE improvement.
• Strong mechanical aptitude and working knowledge of PLC/HMI systems sufficient to diagnose faults; PLC programming is not required.
• Familiarity with MES, OEE platforms such as Redzone, and ERP data.
• OSHA 30-hour or comparable safety training.

Responsibilities

• Analyze OEE, downtime, scrap, and production data by line and shift to identify, prioritize, and address major performance losses.
• Lead projects to reduce ingredient, material, and packaging waste, improve labor utilization, and increase throughput and available capacity.
• Troubleshoot manufacturing issues, lead root cause analysis, implement corrective and preventive actions, verify sustained results, and reduce recurring equipment-related losses.
• Facilitate rapid changeover events using SMED methods, with baselines, targets, action plans, and follow-up.
• Lead startup and commissioning of automated baking lines as the plant's technical liaison with OEMs, controls integrators, and Maintenance.
• Participate in FAT/SAT, equipment debugging, punch-list closure, and ramp-up to rated speed and required product quality.
• Lead TPM activities with Maintenance and Reliability to establish equipment-care routines and reduce repeat breakdowns.
• Diagnose mechanical and automation issues using PLC and HMI alarms, input/output and sensor status, and machine sequences; partner with Maintenance and controls specialists on repairs and countermeasures.
• Support material-handling flow design for new or expanded lines, from raw-material and packaging delivery through finished-goods transfer to shipping.
• Develop, maintain, and audit SOPs for new automated equipment and improved processes, and confirm procedures are practical for employees.
• Lead SOP training for Production, Sanitation, and Maintenance employees, verify understanding, and coach teams to identify and solve problems.
• Support the site's MOS through daily and weekly performance reviews, department metrics, action tracking, and timely follow-through.
• Model safety, food safety, product quality, GMP, and housekeeping expectations; follow equipment safeguards and safe-work procedures during troubleshooting and startup.
• Report hazards and food safety or quality concerns, support audits, and close assigned corrective actions on time.
• Partner respectfully across departments and shifts, encourage employee improvement ideas, and provide hands-on support during startups and other critical operating periods.
• Perform other related duties as assigned to support continuous improvement and business needs.

What This Job Offers

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