Continuous Improvement Engineer

DOUBLE H PACKAGING INC•Warminster Township, PA

About The Position

The Continuous Improvement Engineer identifies, analyzes, and implements opportunities to improve the safety, quality, delivery, productivity, cost, and overall performance of manufacturing operations. This hands-on change agent works across Operations, Engineering, Maintenance, Quality, Finance, IT, and executive leadership to understand problems, develop data-driven solutions, standardize improved processes, and sustain results. The role combines production-floor observation and process engineering with data analysis, technical documentation, training, and communication with leadership. It leads cross-functional improvement projects from problem identification through implementation and sustainment, using measurable baselines and targets to evaluate results. The engineer also develops operational dashboards and reporting, works with ERP and manufacturing systems, and creates and maintains documentation and training materials that support consistent processes. The position is based at Double H Plastics in Warminster and reports to the Continuous Improvement Manager.

Requirements

Bachelor's degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, or another relevant STEM discipline.
Five years of professional experience in a manufacturing environment.
Demonstrated experience in continuous improvement, process engineering, manufacturing engineering, operations engineering, or a related discipline.
Strong proficiency in Microsoft Excel.
Strong proficiency in Microsoft Power BI, including dashboard and data-visualization development.
Experience working with ERP or manufacturing management systems.
Demonstrated ability to conduct time studies, process-flow analysis, value-stream mapping, process observation and evaluation, root-cause analysis, and data analysis.
Exceptional written and verbal communication skills.
Exceptional technical writing and documentation skills.
Ability to communicate effectively with hourly employees, supervisors, managers, engineers, executives, and external stakeholders.
Strong attention to detail and ability to maintain accuracy while managing multiple projects.
Ability to work independently and maintain personal accountability for assignments and commitments.
Ability to conduct professional training sessions and technical presentations.
Ability to work effectively in both an office/data-analysis environment and on the manufacturing floor.

Nice To Haves

Lean Manufacturing or Six Sigma certification.
Experience with process design or manufacturing process development.
Experience with Visual Basic / VBA.
Programming or scripting experience.
Experience developing Excel-based automation tools.
Experience integrating or manipulating data from ERP, MES, CMMS, or other manufacturing systems.
Experience with SQL, databases, APIs, or other data technologies.
Experience with Power BI data modeling, Power Query, and/or DAX.
Experience leading Kaizen events or structured improvement projects.
Experience with capital equipment selection, installation, commissioning, or process validation.
Experience developing Standard Work, SOPs, and Work Instructions.
Experience with Lean tools such as 5S / 6S, Value-Stream Mapping, Standard Work, Visual Management, Kaizen, Root-Cause Analysis, 5-Why, Fishbone/Ishikawa, SMED, OEE, Kanban, and Process Flow Analysis.

Responsibilities

Identify, evaluate, prioritize, and lead continuous improvement opportunities throughout manufacturing operations.
Conduct time studies, work measurement, process-flow evaluations, and value-stream mapping to identify waste, bottlenecks, capacity constraints, and improvement opportunities.
Analyze current-state processes and develop future-state processes that improve efficiency, quality, safety, and throughput.
Lead or support Kaizen, Lean, Six Sigma, and structured problem-solving activities.
Develop and implement process improvements using data, observation, engineering principles, and cross-functional input.
Establish measurable baselines and performance targets before improvements, and monitor results after implementation.
Develop standard work and process controls to sustain improvements; reduce unnecessary steps and variation, improve material flow, and simplify processes.
Support capital equipment evaluations, process design, equipment implementation, and manufacturing process changes.
Develop and maintain Power BI dashboards, reports, KPIs, and visual management tools.
Extract, clean, analyze, and interpret data from ERP and other manufacturing systems; use Excel for analysis, modeling, reporting, and decision support.
Develop automated or semi-automated reporting tools where appropriate and translate operational data into useful information for audiences throughout the organization.
Identify trends, abnormalities, performance gaps, and improvement opportunities through quantitative analysis, and establish data-driven performance measurements.
Work with ERP and manufacturing information systems to understand operational data and identify improvement opportunities in processes, production, inventory, quality, maintenance, and operations.
Partner with IT and functional stakeholders to improve manufacturing-system data accuracy, usability, and effectiveness; assist with ERP process and workflow development, implementation, and standardization.
Identify opportunities to automate manual processes and improve data visibility.
Create and maintain SOPs, work instructions, process documentation and maps, training materials, technical reports, project documentation, process specifications, and visual management materials.
Translate technical processes into clear documentation, establish documentation standards, and ensure documents reflect actual processes and are updated after approved changes.
Develop and conduct training on new or improved processes, systems, equipment, and standard work for employees and stakeholders.
Communicate the rationale and details of process changes, work with employees at all levels to develop practical solutions, and encourage employee participation in improvement opportunities.
Lead cross-functional improvement projects from problem identification through implementation and sustainment; define objectives, scope, timelines, deliverables, measurements, and action plans.
Coordinate stakeholders across Operations, Engineering, Maintenance, Quality, IT, Finance, and other functions.
Present project findings, recommendations, progress, and results to management and executive leadership; facilitate stakeholder meetings professionally.
Challenge existing processes and assumptions when supported by data and engineering analysis, and maintain accountability for projects, action items, deadlines, and deliverables.