Sr. Process Improvement Engineer

Overview BISSELL’s Consumables Manufacturing plant located in Grand Rapids, MI, is a fast-paced, multi-shift operation. It includes operations in blow molding, mix / batching, and multiple liquid-fill packaging lines. The Sr. Process Improvement Engineer is responsible for leading, identifying, and implementing process improvement initiatives throughout the plant that positively impact safety, quality, efficiency, and cost. This position will ensure manufacturability for new products / processes, while also focusing on capacity, improving equipment capabilities, and leading capital projects. The role would perform and establish a variety of functions in the development and / or improvement of production methods, processes, machine setups, equipment commissioning & upgrades, tooling and designs used in the manufacturing of consumables products. The position will also investigate and recommend areas for cost reduction, perform computations, collect and analyze engineering data perform feasibility studies, and prepare high level reports, summaries and analyses. Responsibilities Monitor manufacturing processes daily to identify trends and out-of-control situations and provide solutions according to urgency and importance. Estimated 75% of time is spent on Manufacturing floor. Collect, analyze, and report data for process control and capability improvement. Lead and participate in capital projects for plant capacity increase, new product introductions and plant upgrades. Lead material development & investigate alternative quality and cost-effective material to existing. Lead complex problem-solving initiatives to tackle quick resolution of issues. Lead continuous improvement techniques including Design of Experiments, Cycle Time improvement, Just-in-Time, Change Over Process Improvement, Lean Six Sigma, 6S, problem solving, Total Productive Maintenance, etc. Conduct process and product quality audits to ensure compliance with quality management systems. Develop or maintain performance indicators on a weekly & monthly basis to ensure the process is meeting quality and productivity targets. Perform root cause analysis on reasons for trends, equipment issues- importantly repeat equipment issues, and process drifts. Responsible for Work Instructions, Point of Use Guides and SOP’s generation for various plant functions and operations including training of personnel and internal communication for updates. Implement process changes or new development product trials as directed by R&D. Responsible for reviewing equipment / process performance and initiating projects to upgrade / streamline processes or procedures. Responsible for providing and directing timely transfers of new processes, methods, and techniques to assigned production lines to ensure timely and effective startup of new / revised products and / or processes. Qualifications Required Core Competencies : Perform at a high level in a fast-paced environment while managing multiple projects at once. Lead and facilitate cross-functional teams and successfully guide others to successful project completion. Mitigate risks and make project-related decisions with limited coaching. Utilize basic Project Management tools including project plans, Gantt charts, critical path analysis, risk registers, capacity analysis, etc. Excellent critical thinking and problem-solving skills Be a self-starter that can perform well without constant supervision. Communicate and present clearly and effectively. Strong collaboration and decision-making skills Excellent troubleshooting skills and attention to detail Excellent documentation and organizational skills Required Experience / Education : Degree Minimum : Bachelor’s Degree Specific Concentration : Engineering Experience Level : Understanding of Lean Six Sigma Black Belt Certification with proven track record of identifying and delivering continuous improvement opportunities. Minimum 5 years of experience in a Manufacturing environment Demonstrated ability to anticipate problems and formulate contingency plans. SPECIALIZED TRAINING OR SKILLS REQUIRED : This position requires the ability to manage the flow of data, perform analysis, generate summary reports, and communicate by voice or data while being connected in the office, at home or while traveling by laptop or mobile device regularly without regard to time zone or day of the week.