Process Engineer - Kaizen

As the North American headquarters for G-TEKT Corporation, Jefferson Industries actively participates in the Global Automotive Industry. As part of our involvement, Jefferson Industries Corporation offers design and development for press dies and other tools necessary to produce automotive products. We embrace programs for product development including product design review and Advanced Product Quality Planning. Our facilities support high quality product manufacturing, and we provide a timely and flexible approach to meeting the needs of our customers.

We are actively seeking a Process Engineer to join our Kaizen team on 1st shift (core schedule, Monday - Friday, 6:00 am to 2:30 pm or 7:30 am to 4:00 pm)

Position Summary

The Process Engineer applies advanced engineering principles, technical analysis, and independent professional judgment to evaluate, develop, implement, and continuously improve manufacturing processes within a high-volume automotive stamping environment.

As a member of the Kaizen Department, this position is responsible for analyzing complex manufacturing processes and recommending engineering solutions that improve safety, quality, productivity, equipment utilization, material flow, process capability, and manufacturing cost. The Process Engineer uses specialized engineering knowledge to evaluate production systems, identify root causes of process and equipment performance issues, develop and evaluate alternatives, and determine appropriate engineering countermeasures.

The position maintains a strong presence within manufacturing operations and collaborates with Production, Maintenance, Quality, Tool & Die, Material Services, Safety, and plant leadership to develop and implement sustainable improvements. Primary areas of focus include OEE, press performance, cycle time, downtime, scrap and rework, die changeover, labor efficiency, material flow, ergonomics, standardized work, process capability, and manufacturing process stability.

The position requires the consistent exercise of discretion and professional engineering judgment in analyzing manufacturing conditions, evaluating alternatives, establishing process requirements, and developing solutions to complex manufacturing problems.

Essential Duties and Responsibilities

Engineering and Process Improvement

• Apply engineering principles and analytical methods to evaluate manufacturing processes, equipment performance, production systems, material flow, and process capability.
• Independently analyze complex manufacturing problems and develop engineering recommendations and countermeasures.
• Design, develop, test, and implement process improvements to improve safety, quality, cost, delivery, productivity, and manufacturing performance.
• Evaluate alternative processes, equipment configurations, manufacturing methods, and workflows and recommend solutions based on engineering analysis, operational requirements, risk, and cost.
• Establish appropriate process parameters, performance measures, and methods for evaluating implemented improvements.
• Provide technical and engineering support for new or modified processes, equipment, tooling, and manufacturing methods.

Continuous Improvement and Kaizen

• Lead and participate in Kaizen activities focused on measurable improvements to manufacturing performance.
• Apply Lean Manufacturing methodologies including 5S, Standardized Work, Value Stream Mapping, visual management, SMED, PDCA, A3 problem solving, mistake-proofing/poka-yoke, and waste elimination.
• Conduct engineering studies, process observations, time studies, capacity analyses, and workflow evaluations to identify constraints and improvement opportunities.
• Develop current-state and future-state processes and recommend appropriate implementation strategies.
• Establish measurable project objectives and evaluate results following implementation.
• Develop controls and processes to sustain improvements.

Stamping Process Engineering

• Analyze stamping operations to improve press utilization, throughput, cycle time, die-change efficiency, material utilization, process capability, and process stability.
• Analyze production losses associated with press downtime, micro-stoppages, coil changes, die changes, equipment conditions, material handling, tooling, and quality concerns.
• Partner with Production, Maintenance, and Tool & Die to determine root causes of recurring process and equipment losses and develop appropriate engineering countermeasures.
• Evaluate presses, feeders, straighteners, coil-handling systems, transfer systems, conveyors, scrap systems, tooling, and related manufacturing processes.
• Develop solutions to reduce scrap and rework and improve manufacturing capability.
• Apply SMED principles and engineering analysis to reduce setup and die-change times.

Manufacturing Analysis and Problem Solving

• Analyze OEE, availability, performance, quality losses, cycle time, downtime, scrap, changeover time, production attainment, and labor utilization.
• Interpret manufacturing data to identify trends, abnormal conditions, process variation, constraints, and improvement opportunities.
• Lead structured root-cause analysis using appropriate methodologies, including 5 Why, Fishbone/Ishikawa, Pareto analysis, PDCA, A3, and DMAIC.
• Distinguish symptoms from root causes and develop technically appropriate countermeasures.
• Evaluate corrective actions to confirm effectiveness and establish controls to minimize recurrence.
• Develop business cases for proposed improvements, including projected capacity, labor, scrap, quality, productivity, and cost impacts.

Process Design, Material Flow and Ergonomics

• Develop and improve manufacturing layouts, work sequences, operator balance, material presentation, work-in-process locations, and material-flow strategies.
• Apply engineering principles to reduce unnecessary movement, handling, waiting, transportation, inventory, and other forms of manufacturing waste.
• Evaluate proposed process changes for potential safety and ergonomic considerations.
• Collaborate with Safety, Operations, and other appropriate functions to incorporate ergonomic and risk-reduction considerations into manufacturing processes.
• Develop standardized work and appropriate process controls following implementation of improvements.

Project Implementation

• Develop engineering project scopes, schedules, technical requirements, cost estimates, and implementation plans.
• Coordinate manufacturing trials and implementation of new or modified processes, fixtures, tooling, equipment, or manufacturing methods.
• Establish technical requirements and work with equipment manufacturers, integrators, suppliers, and internal departments as appropriate.
• Evaluate project outcomes against established engineering and operational objectives.
• Communicate project status, technical findings, risks, recommendations, and results to plant leadership and other stakeholders.
• Maintain appropriate engineering and process documentation.

JIC associates are eligible for a comprehensive and competitive compensation and benefits package, including:

Compensation:

• Weekly Pay
• Holiday Pay
• Shutdown Pay
• Summer - around July 4th holiday
• Winter - around Christmas/New Year's holiday
• Bi-annual TEAM Achievement Bonus
• Annual Profit Share Bonus

Benefits:

• Paid vacation
• Three (3) medical options to allow you the flexibility to choose what level of coverage best fits you and your family's needs
• Flexible Spending Accounts (medical and dependent care)
• Free Dental & Vision (must be enrolled in medical benefit)
• Voluntary Supplemental
• Life Insurance
• Hospital Indemnity
• Group Accident
• Critical Illness
• Company-paid
• Short-term Disability
• Long-term Disability
• Basic Life & AD&D
• Employee coverage - 2 times annual base earnings
• Spouse - flat $10,000
• Child - flat up to $5,000
• 401k Retirement
• Traditional Contribution
• ROTH Contribution
• Company Match
• 401k Retirement Profit Share
• Funded 100% by Company based on a percentage of eligible earnings each quarter
• Eligible regardless of participation in 401K Retirement
• Referral Bonus
• Tuition Reimbursement
• Safety Equipment Reimbursement (safety boots & prescription safety glasses)
• Company-paid uniforms, including laundering
• Tickets@Work - web-based discount program (hotels, car rental, tickets, etc.)

Qualifications

Required Qualifications

Education

• Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or another directly related engineering discipline from an accredited college or university.

Experience

• Three or more years of manufacturing engineering, process engineering, industrial engineering, or continuous improvement experience preferred.
• Automotive manufacturing experience preferred.
• Experience with metal stamping, press operations, tooling, or high-volume manufacturing highly desirable.
• Demonstrated experience applying engineering principles to manufacturing process improvement and problem solving preferred.

Knowledge, Skills and Abilities

• Knowledge of engineering principles applicable to manufacturing and industrial processes.
• Strong knowledge of Lean Manufacturing and continuous improvement methodologies.
• Working knowledge of OEE and manufacturing performance measurement.
• Strong analytical, technical, and structured problem-solving capabilities.
• Ability to analyze manufacturing data and translate findings into engineering recommendations and solutions.
• Ability to read and interpret technical drawings, manufacturing layouts, specifications, and process documentation.
• Proficiency with Microsoft Excel or comparable analytical tools.
• CAD and manufacturing-layout experience preferred.
• Lean Six Sigma Green Belt or comparable continuous improvement training preferred.
• Strong project management, communication, facilitation, and organizational skills.
• Ability to effectively collaborate with employees across Production, Maintenance, Tool & Die, Quality, Logistics, Safety, Engineering, and plant leadership.

Essential Functions

The employee must be able to perform the essential functions of the position, with or without reasonable accommodation, including:

• Regularly access and observe manufacturing processes and equipment to evaluate operating conditions, collect relevant information, investigate manufacturing problems, and verify process improvements.
• Move within office and manufacturing areas as necessary to perform process evaluations, collaborate with employees, and oversee project implementation.
• Observe and evaluate manufacturing processes, equipment conditions, material flow, and work methods using appropriate tools, technology, assistance, or other reasonable accommodations where applicable.
• Read, analyze, develop, and communicate technical information, including engineering data, drawings, specifications, reports, and manufacturing information.
• Communicate and collaborate effectively with employees, vendors, suppliers, and leadership through appropriate communication methods.
• Operate or use computers, engineering software, measuring devices, and other tools necessary to perform the position’s essential functions.
• Work in and around active manufacturing operations while complying with applicable safety requirements.
• Respond to manufacturing issues and support project implementation, equipment trials, or process changes as business and production needs reasonably require.

Work Environment

Work is performed in both office and automotive manufacturing environments. Manufacturing areas may include exposure to industrial machinery, stamping presses, moving equipment, material-handling equipment, elevated noise levels, vibration, oils or lubricants, varying temperatures, and other conditions typical of an automotive stamping operation.

Use of required personal protective equipment and compliance with applicable plant safety requirements are required when entering designated manufacturing areas.

Reasonable Accommodation

Reasonable accommodations may be made to enable qualified individuals with disabilities to perform the essential functions of the position, unless doing so would impose an undue hardship, in accordance with applicable law.

Equal Employment Opportunity

The Company provides equal employment opportunities to qualified applicants and employees and prohibits discrimination on the basis of any characteristic protected by applicable federal, state, or local law.