Continuous Improvement Leader

Pennsylvania Transformer Technology LLC • Canonsburg, PA

1d • Hybrid

About The Position

Pennsylvania Transformer is seeking a results-driven Continuous Improvement (CI) Leader to drive operational excellence across our Dead Tank Breaker manufacturing operations. This role will lead enterprise-wide Lean Six Sigma (LSS) initiatives across manufacturing, engineering, supply chain, quality, and business operations to maximize production efficiency, reduce waste, and support scalable growth. The ideal candidate is a hands-on leader who can coach teams at all levels, drive measurable results, and build a self-sustaining culture of continuous improvement.

Requirements

• Bachelor's degree in Engineering, Operations Management, Industrial Engineering, or related field.
• Lean Six Sigma Black Belt certification (or equivalent demonstrated experience).
• 7+ years of progressive experience in manufacturing continuous improvement, preferably in heavy electrical equipment, power apparatus, or industrial manufacturing.
• Demonstrated track record leading Kaizen events and delivering measurable cost/efficiency improvements.
• Hands-on leadership and shop floor presence.
• Ability to influence without direct authority across departments.
• Strong facilitation, coaching, and training skills.
• Data-driven and results-oriented mindset.
• Comfortable balancing strategic initiatives with tactical, day-to-day floor issues.
• Strong analytical, project management, and change management skills.
• Experience with ERP/MES systems and data-driven decision making.

Nice To Haves

• Experience in transformer, switchgear, or circuit breaker manufacturing.
• Familiarity with high-voltage testing processes and dielectric/mechanical test standards (IEEE, ANSI, IEC).
• Six Sigma Master Black Belt certification.
• Experience leading union and non-union manufacturing environments.

Responsibilities

• Develop and execute the site-wide Continuous Improvement strategy aligned with production, quality, and business goals for dead tank breaker manufacturing.
• Partner with plant management, engineering, and business unit leaders to identify high-impact improvement opportunities.
• Establish CI governance structure, project pipelines, and prioritization frameworks.
• Report improvement metrics, savings, and progress to executive leadership.
• Lead value stream mapping across dead tank breaker production lines (fabrication, tank assembly, bushings, interrupters, control cabinets, final assembly, testing).
• Identify and eliminate bottlenecks in welding, machining, painting, assembly, and high-voltage testing operations.
• Reduce cycle time, work-in-process (WIP), and non-value-added activities across the production floor.
• Drive standard work development and visual management systems on the shop floor.
• Partner with production supervisors to implement daily management systems (tiered huddles, gemba walks, andon systems).
• Lead root cause analysis and corrective action efforts for defects, rework, and test failures.
• Apply Design of Experiments (DOE) and Statistical Process Control (SPC) to critical manufacturing processes (welding parameters, tank sealing, dielectric testing).
• Reduce scrap, rework, and warranty-related costs through process capability improvements.
• Support first-pass yield improvement initiatives in testing and final inspection.
• Improve material flow, kitting, and point-of-use delivery to reduce line-side inventory and stockouts.
• Lead improvement projects in order-to-cash, engineering-to-production handoffs, and procurement lead times.
• Support S&OP (Sales & Operations Planning) process improvements to align capacity with demand.
• Identify automation and digital transformation opportunities (MES, IIoT, digital work instructions).
• Train and mentor employees at all levels in Lean and Six Sigma methodologies (Yellow Belt, Green Belt, Black Belt curriculum).
• Certify and develop internal Green Belts/Black Belts to build a distributed CI capability.
• Facilitate Kaizen events, Rapid Improvement Workshops, and problem-solving A3s.
• Champion employee-driven suggestion systems and recognition programs.
• Foster a culture of daily continuous improvement, safety, and accountability.
• Own the CI project pipeline with tracked financial impact (cost savings, cost avoidance, productivity gains).
• Manage capital project justifications tied to efficiency improvements.
• Present business cases and ROI analysis to senior leadership.
• Track and report OEE (Overall Equipment Effectiveness), throughput, safety, and quality KPIs.
• All other duties as assigned.

Benefits

• Competitive salary
• Health, dental, and vision insurance
• 401(k) with company match
• Paid time off and holidays
• Professional development, training, and certification support (e.g., Lean Six Sigma)

What This Job Offers

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