Continuous Improvement Process Engineer

Samuel, Son & Co. • Markham, ON

2d • CA$93,840 - CA$129,030

About The Position

The Continuous Improvement Process Engineer will be responsible for improving process yield, scrap, rework, and manufacturing efficiency. This role involves analyzing processes, planning workflow, space requirements, and equipment layout, and coordinating input across multiple teams. The engineer will focus on maximizing cost effectiveness, scrap reduction, Overall Equipment Effectiveness (OEE), Single Minute Exchange of Die (SMED), mill uptime, and reliability. They will also facilitate time studies, capacity analysis, and process layouts to optimize cost and drive value stream improvements. The position requires assisting in corrective actions using various problem-solving tools, participating in quality management systems, and recommending product changes. The engineer will develop innovative solutions for complex manufacturing problems by identifying and implementing advanced manufacturing processes, conducting process analysis, and gathering operator feedback. Preparation of documentation for new processes, reports summarizing process information, and testing process capabilities to ensure product and process quality are also key responsibilities. Determining the root cause of failures using statistical methods and recommending changes to design, tolerances, or processing methods is essential.

Requirements

• Bachelor’s degree in Industrial Engineering or a related Engineering field.
• Proven 2-3 years of Process Engineering experience preferably in Metal Tube, Aerospace or other related industry.
• Spearheads Yield, VSM, Rework, Time Study Analysis, SMED, OEE, Scrap & Space Optimization Projects.
• Strong analytical and Problem-Solving skills utilizing Lean Six Sigma methodologies, 8D, 5 Why, Design of Experiment, etc.
• Knowledge of Lean, Six Sigma or other improvement methodologies. L6S GB or BB Certification.
• Data-driven mindset with proficiency in data analysis tools.
• Must be able to use Excel, Word, PowerPoint, Visio, Power BI, SQL, Tableau, Python, AutoCAD, Solid Works, Apollo.
• Has working knowledge of engineering domain principles and techniques, product functionality, industry practices, regulations, and policies.
• General knowledge of other related engineering and technical areas and the ability to analyze complex technical issues.
• Excellent communication and interpersonal skills, with a customer-focused mindset.
• Ability to work with general objectives regarding projects and team goals; applies judgment in selecting procedures and techniques that should be applied.
• Works collaboratively in a team environment.
• Demonstrates a positive attitude towards safety and models safety for other employees at all times.
• Understand that it is mandatory to use and/or wear all personal protective equipment provided by the Company.
• Reports all accidents, incidents and near misses and supports in determining corrective actions to eliminate workplace hazards.
• Practices safe work habits as detailed in Samuels/ATC’s safety policies, procedures, C.S.A and the Occupational Health & Safety Act of Ontario.
• Understands and completes necessary health & safety training through Samuel’s Safety Training program and ensures renewal training is completed as per company requirements.

Nice To Haves

• Knowledge of JDE systems

Responsibilities

• Improve process yield, scrap, rework, and manufacturing efficiency by analyzing the process and planning workflow, space requirements, and equipment layout.
• Coordinate input that may cross multiple teams or areas; make recommendations and implement changes.
• Maximize Cost Effectiveness, Scrap Reduction, Overall Equipment Effectiveness (OEE), Single Minute Exchange of Die (SMED), Mill Uptime, and Reliability towards manufacturing flow, processes, and equipment.
• Facilitate time studies, capacity analysis, space optimization, and process lay-outs to support the vision of flow and optimize cost through driving process efficiencies and value stream improvements.
• Assist in technical input to perform corrective actions using 8-D format, fault trees, cause & effect diagrams, 5 Whys, A3, Design of Experiment and other tools; and to communicate data internally and externally.
• Participate in the AS9100/ISO9001/IATF quality management system requirements.
• Refine and enhance processes by applying continuous improvement and key Lean manufacturing/production principles and techniques to areas of production.
• Recommend product changes/improvements.
• Identify and implement solutions for issues relating to safety, quality, productivity, and cost reductions.
• Develop innovative solutions to complex manufacturing production problems through identification and implementation of advanced manufacturing processes including conducting process analysis, applying knowledge of product design and materials, and soliciting observations from the operators/production technicians.
• Prepare documentation for new manufacturing processes.
• Prepare reports summarizing analyzed process information and trends.
• Assure product and process quality by testing process capabilities and establishing standards to confirm and validate manufacturing process requirements.
• Determine root cause of failures using statistical methods (e.g., design of experiment, SPC) that may result in recommended changes in design, tolerances, or processing methods.
• Support the VSM, lead hands, operators and transactional support groups in recovery and preventive actions for rework, setup, and changeovers.
• Application of Lean Six Sigma Methodologies (DMAIC, DMADV).
• Use the necessary lean tools, supplies and guidance to improve effectiveness.
• Reinforce 5S; Idea Management; Time Studies, Space optimization, Kaizen, Kanban, Hoshin Kanri, Poka-Yoke; SIPOC; SMED; Obeya; Leader Standard Work; Gemba and Value Stream Mapping.
• Collaborate with management to prioritize improvement efforts based on data, impact, and feasibility.
• Use pain point logs, cause-and-effect diagrams, 5 Whys, and other Lean Six Sigma tools to identify root causes at the real place (Gemba).
• Facilitation of Project Drilldown Analysis; Project Charters; 8D; A3; Kaizen.
• Collaborate with Management, Quality Assurance, Group Engineering, and other departments to execute and sustain improvements.
• Internal Benchmark: Observe and assist operators to identify real issues, wastes, constraints and root causes.
• Functional Benchmark: Research operational excellence relative to Process Engineering improvements across similar or divergent industries especially Tubing, Aerospace and Data Center.
• Partner with VSM, QA, CI, Maintenance to ensure equipment robustness and reduce operator struggles.
• Collaborate with Management and HR for alignment, morale, and training.
• Support business expansion by improving employee engagement, process capability, compliance, and reducing Cost of Poor Quality (COPQ).
• Apply mental frameworks in day-to-day improvement work, empowering operators to stop the process when issues occur and building quality at the source.
• Foster an environment where learning, feedback, and small daily improvements are celebrated.
• Simplify complex concepts by explaining them in clear, everyday language to teach operators and teams.
• Actively participate in the 5S Big Clean-Up Activities and support the ATC 5S Standardization.
• Reinforce Value Stream Mapping Activities by providing updated VSM cycle time, standard time, mapping, SIPOC analysis.
• Spearhead CI Projects related to Yield, Scrap, OEE, SMED, Mill Up-time Projects.
• Communicate with the Value Stream Managers, operators, lead hands, and QA/QC to understand ongoing issues and goals.
• Engage in the ATC TIBS Meeting and challenge the team on the OFI’s in the metrices in the TIBS relative to Safety, Quality, Delivery and Cost.
• Conduct gemba walks to observe operations, identify wastes, and record improvement opportunities.
• Act on Lean Quick Wins opportunities that are low cost, low effort but high impact improvements.
• Reinforce and support 5S standards at workstations. Provide operators with proper tools and supplies to optimize preparedness and effectiveness.
• Engage operators in quick 5–10 minute micro-learning moments to reinforce Lean principles.
• Provide support to maintenance when equipment issues impact robustness or productivity.
• Communicate process engineering improvement projects and status to management and relevant departments.
• Review log data and trends to identify recurring issues or variations.
• Meet with VSM, QA, Group Engineering, and Lean teams to align improvement priorities.
• Conduct Root Cause Analysis on one key recurring issue per week.
• Update Process Engineering KPI’s and reports related to Yield, Scrap, VSM, OEE, SMED, Mill Uptime.
• Present a monthly improvement report summarizing key projects completed or initiated and quantified waste reduction and process improvements.
• Lead or co-lead a small-to-medium Lean improvement project with cross-functional collaboration.
• Conduct internal benchmarking reviews to compare process capability and performance.
• Review and refresh training content for learning sessions.
• Support and evaluate 5S, Idea Management, Kaizen sustainability and corrective measures for drift.
• Report PE Metrices trends and process stability metrics to management.
• Perform gap analysis to document current status versus past performance, enabling measurable progress tracking.
• Facilitate projects assigned by management, forming cross-functional teams of Yellow Belts and process owners to execute them collaboratively.
• Maintain continuous work to sustain all improvement initiatives and ensure gains are not lost.

Benefits

• Countless opportunities for team members to develop and grow in their careers.
• Empowerment to make decisions on the job.
• Opportunity to be part of driving positive change within the organization and communities.
• Dynamic, supportive and welcoming workplace.
• Programs, culture and opportunities to make a mark and grow a career.
• Culture of equality.
• Respect and integrity are at the core.
• Commitment to building and creating an environment that is open and welcoming for everyone.

What This Job Offers

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