FerroWorks has locations in Pittsburgh, McKees Rocks, including McConway and Torley and Standard Forged, which have been in continuous operations since 1869, the same year the first US transcontinental railroad was completed. We have been able to meet the needs of our customers with a steady, dependable and economical supply of high-quality railroad industry products. As McConway is the original designers of the first standard automatic coupler, continued innovation and craftsmanship have and has led to a product line that includes every AAR approved coupler as well as custom coupler solutions, which are all proudly cast in the US. McConway & Torley is looking for a highly motivated and results-driven Continuous Improvement Engineer to join our steel foundry team. You will play a critical role in driving process optimization, enhancing operational efficiency, and fostering a culture of continuous improvement throughout the facility. This individual will utilize Lean Manufacturing principles, Six Sigma methodologies, and other process improvement tools to achieve measurable results in quality, productivity, and cost reduction.
Some of your key responsibilities will include:
- Analyzing current manufacturing processes to identify inefficiencies, bottlenecks, and waste
- Developing and implementing strategies to improve throughput, reduce cycle times, and enhance overall efficiency
- Lead Lean initiatives such as value stream mapping, 5S, and Kaizen events
- Utilize Six Sigma tools to analyze data, define problems, and implement sustainable solutions
- Collect, analyze, and interpret production data to identify trends and opportunities for improvement. Prepare detailed reports and present findings to stakeholders
- Collaborating with production, quality, maintenance, and engineering teams to identify improvement opportunities and implement best practices
- Identify cost-saving opportunities through material efficiency, energy optimization, and labor utilization improvements
- Delivering training and guidance to employees at all levels on continuous improvement tools and methodologies to ensure sustainable cultural transformation
- Investigating quality issues and process deviations using tools such as 5-Why, Fishbone diagrams, and Failure Mode and Effects Analysis (FMEA)
- Collaborating on initiatives to reduce environmental impact, improve energy efficiency, and enhance sustainability in foundry operations
Required Qualifications:
- Some experience including internship experience in a manufacturing environment, preferably in a steel foundry or similar heavy industry
Preferred Qualifications:
- Proven experience leading Lean, Six Sigma, or other process improvement initiatives
- Certifications: Lean Six Sigma Green Belt or Black Belt certification is highly preferred
- Strong analytical skills with proficiency in statistical analysis tools (e.g., Minitab, Excel, Power BI)
- Excellent problem-solving and decision-making capabilities
- Strong project management skills with the ability to manage multiple initiatives simultaneously
- Effective communication and interpersonal skills to influence and drive change
Education:
- Bachelor’s degree in Engineering (Industrial, Mechanical, Metallurgical, or related field) is required
Benefits:
- Health & Pharmacy
- Dental & Vision
- Critical Illness
- Flexible Spending Accounts
- Company Paid Life & AD&D Insurance
- Voluntary Life & AD&D Insurance
- 401(k) W/Company Match
- Short-Term Disability
- Voluntary Long-Term Disability
- Employee Assistance Program