Continuous Improvement Engineer Aero Industries, Inc. - 3.4 Indianapolis, IN Job Details Full-time $69,465.13 - $83,656.92 a year 16 hours ago Qualifications Defect resolution root cause analysis Mechanical design Spreadsheets Six Sigma methodology implementation Project management experience in manufacturing Change management Manufacturing facility experience Data interpretation Industrial engineering Leading team collaboration initiatives Managing projects Lean Six Sigma Green Belt Productivity software Quality improvement programs in engineering Cross-functional team management Manufacturing company experience Certified Quality Engineer Cross-functional communication Full Job Description

COMPANY SUMMARY

Aero Industries, Inc. (Aero or the "Company"), is a global leader in the manufacturing of tarp systems and trailer accessories. With a long track record of success, a reputation for superior capabilities and long-standing customer relationships, Aero represents a compelling platform for growth. Headquartered in Indianapolis, Indiana, Aero also serves customers through satellite locations in Nebraska, Ohio, and a nationwide network of dealers. This 78-year-old, family-owned business has endured through a dedicated workforce and a commitment to support its employees.

PURPOSE AND SCOPE

The Continuous Improvement / Operational Excellence Engineer leads enterprise-wide initiatives to enhance manufacturing performance through process optimization, standardization, and continuous improvement. This role serves as both a technical expert and change agent, partnering with Operations, Engineering, Quality, Supply Chain, and Project teams to identify opportunities, reduce variability, improve process capability, eliminate waste, and strengthen operational discipline. Using Lean, Six Sigma, 8D, Root Cause Analysis (RCA), and other structured problem-solving methodologies, the engineer drives measurable improvements in safety, quality, delivery, cost, productivity, and customer satisfaction. The role also provides direct manufacturing support by optimizing production processes, resolving technical issues, and implementing sustainable improvements. By balancing daily operational needs with long-term strategic initiatives, the Continuous Improvement Engineer helps ensure safe, efficient, and high-performing manufacturing operations.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Lead Lean Manufacturing and Continuous Improvement initiatives focused on waste reduction, productivity improvement, labor efficiency, throughput optimization, and cost reduction. Facilitate Kaizen events, value stream mapping activities, process improvement workshops, and cross-functional problem-solving sessions. Utilize Lean, Six Sigma, DMAIC, 8D, and Root Cause Analysis methodologies to identify root causes, implement corrective actions, and sustain improvements. Analyze production metrics, downtime trends, quality metrics, scrap rates, labor performance, and Overall Equipment Effectiveness (OEE) to identify improvement opportunities. Develop and maintain standard work, visual management systems, process metrics, and performance dashboards. Train and coach supervisors, team leaders, and employees on Lean principles, continuous improvement tools, and structured problem-solving methods. Manufacturing Process Engineering Evaluate manufacturing processes based on quality, productivity, safety, and efficiency criteria. Study production processes, machine requirements, and equipment performance to identify opportunities for optimization. Design, develop, test, and improve manufacturing processes, equipment, tooling, fixtures, and production systems. Develop and maintain Standard Operating Procedures (SOPs), work instructions, process control plans, and manufacturing documentation. Support new product introductions to ensure manufacturability, quality, and operational efficiency. Assist with the selection, installation, validation, and implementation of manufacturing equipment and automation solutions. Production Floor Leadership Maintain a consistent presence on the production floor to support operations and identify improvement opportunities. Troubleshoot daily production, assembly, fabrication, material flow, and equipment-related issues impacting safety, quality, cost, or delivery. Collaborate with supervisors and production personnel to improve workflows, remove bottlenecks, and maximize resource utilization. Optimize facility layouts, work cells, production lines, and material movement to improve operational efficiency and safety. Lead implementation and sustainment activities for process and operational improvements. Quality, Safety & Compliance Partner with Quality Assurance to investigate nonconformances, recurring defects, and customer concerns. Lead root cause investigations and corrective action implementation for manufacturing and quality issues. Ensure manufacturing processes comply with company safety requirements, environmental regulations, and industry standards. Promote a culture of safety, accountability, operational excellence, and continuous improvement. Project Management Lead manufacturing improvement projects from concept through implementation and sustainment. Develop project plans, establish timelines, coordinate resources, and communicate project progress to leadership. Quantify and report project benefits including cost savings, productivity gains, quality improvements, and operational efficiencies.

REQUIRED KNOWLEDGE, SKILLS, AND ABILITIES

Knowledge of Lean Manufacturing, Six Sigma, Kaizen, Root Cause Analysis, and structured problem-solving methodologies. Strong understanding of manufacturing processes, fabrication methods, tooling, production systems, and quality systems. Excellent analytical and data interpretation skills. Strong project management, planning, and organizational skills. Effective interpersonal, communication, coaching, and facilitation skills. Ability to work effectively with cross-functional teams and influence change. Proficiency in Microsoft Office applications, especially Excel.

EDUCATION AND EXPERIENCE

Required Bachelor's degree in industrial engineering, Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, or a related technical field. Minimum three (3) years of manufacturing engineering, process engineering, continuous improvement, or operational excellence experience within a manufacturing environment. Preferred Lean Six Sigma Green Belt certification. Lean Six Sigma Black Belt certification. Experience with CAD software, including SolidWorks or AutoCAD. Experience with ERP, MES, or manufacturing information systems. Experience supporting fabrication, welding, assembly, or industrial manufacturing operations.

PHYSICAL REQUIREMENTS

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform these functions. Frequent walking throughout manufacturing and warehouse facilities. Ability to stand for extended periods while supporting production operations. Ability to occasionally lift and/or move up to 20 pounds. Ability to work safely in manufacturing environments with varying temperatures and noise levels. Occasional travel may be required based on business needs.

DISCLAIMER

This job description is intended to describe the general nature and level of work performed by employees assigned to this position. It is not intended to be an exhaustive list of all duties, responsibilities, and qualifications required. Management reserves the right to modify responsibilities and requirements as business needs dictate.

COMPANY SUMMARY

Aero Industries, Inc. (Aero or the "Company"), is a global leader in the manufacturing of tarp systems and trailer accessories. With a long track record of success, a reputation for superior capabilities and long-standing customer relationships, Aero represents a compelling platform for growth. Headquartered in Indianapolis, Indiana, Aero also serves customers through satellite locations in Nebraska, Ohio, and a nationwide network of dealers. This 78-year-old, family-owned business has endured through a dedicated workforce and a commitment to support its employees.

PURPOSE AND SCOPE

The Continuous Improvement / Operational Excellence Engineer leads enterprise-wide initiatives to enhance manufacturing performance through process optimization, standardization, and continuous improvement. This role serves as both a technical expert and change agent, partnering with Operations, Engineering, Quality, Supply Chain, and Project teams to identify opportunities, reduce variability, improve process capability, eliminate waste, and strengthen operational discipline. Using Lean, Six Sigma, 8D, Root Cause Analysis (RCA), and other structured problem-solving methodologies, the engineer drives measurable improvements in safety, quality, delivery, cost, productivity, and customer satisfaction. The role also provides direct manufacturing support by optimizing production processes, resolving technical issues, and implementing sustainable improvements. By balancing daily operational needs with long-term strategic initiatives, the Continuous Improvement Engineer helps ensure safe, efficient, and high-performing manufacturing operations.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Lead Lean Manufacturing and Continuous Improvement initiatives focused on waste reduction, productivity improvement, labor efficiency, throughput optimization, and cost reduction. Facilitate Kaizen events, value stream mapping activities, process improvement workshops, and cross-functional problem-solving sessions. Utilize Lean, Six Sigma, DMAIC, 8D, and Root Cause Analysis methodologies to identify root causes, implement corrective actions, and sustain improvements. Analyze production metrics, downtime trends, quality metrics, scrap rates, labor performance, and Overall Equipment Effectiveness (OEE) to identify improvement opportunities. Develop and maintain standard work, visual management systems, process metrics, and performance dashboards. Train and coach supervisors, team leaders, and employees on Lean principles, continuous improvement tools, and structured problem-solving methods. Manufacturing Process Engineering Evaluate manufacturing processes based on quality, productivity, safety, and efficiency criteria. Study production processes, machine requirements, and equipment performance to identify opportunities for optimization. Design, develop, test, and improve manufacturing processes, equipment, tooling, fixtures, and production systems. Develop and maintain Standard Operating Procedures (SOPs), work instructions, process control plans, and manufacturing documentation. Support new product introductions to ensure manufacturability, quality, and operational efficiency. Assist with the selection, installation, validation, and implementation of manufacturing equipment and automation solutions. Production Floor Leadership Maintain a consistent presence on the production floor to support operations and identify improvement opportunities. Troubleshoot daily production, assembly, fabrication, material flow, and equipment-related issues impacting safety, quality, cost, or delivery. Collaborate with supervisors and production personnel to improve workflows, remove bottlenecks, and maximize resource utilization. Optimize facility layouts, work cells, production lines, and material movement to improve operational efficiency and safety. Lead implementation and sustainment activities for process and operational improvements. Quality, Safety & Compliance Partner with Quality Assurance to investigate nonconformances, recurring defects, and customer concerns. Lead root cause investigations and corrective action implementation for manufacturing and quality issues. Ensure manufacturing processes comply with company safety requirements, environmental regulations, and industry standards. Promote a culture of safety, accountability, operational excellence, and continuous improvement. Project Management Lead manufacturing improvement projects from concept through implementation and sustainment. Develop project plans, establish timelines, coordinate resources, and communicate project progress to leadership. Quantify and report project benefits including cost savings, productivity gains, quality improvements, and operational efficiencies.

REQUIRED KNOWLEDGE, SKILLS, AND ABILITIES

Knowledge of Lean Manufacturing, Six Sigma, Kaizen, Root Cause Analysis, and structured problem-solving methodologies. Strong understanding of manufacturing processes, fabrication methods, tooling, production systems, and quality systems. Excellent analytical and data interpretation skills. Strong project management, planning, and organizational skills. Effective interpersonal, communication, coaching, and facilitation skills. Ability to work effectively with cross-functional teams and influence change. Proficiency in Microsoft Office applications, especially Excel.

EDUCATION AND EXPERIENCE

Required Bachelor's degree in industrial engineering, Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, or a related technical field. Minimum three (3) years of manufacturing engineering, process engineering, continuous improvement, or operational excellence experience within a manufacturing environment. Preferred Lean Six Sigma Green Belt certification. Lean Six Sigma Black Belt certification. Experience with CAD software, including SolidWorks or AutoCAD. Experience with ERP, MES, or manufacturing information systems. Experience supporting fabrication, welding, assembly, or industrial manufacturing operations.

PHYSICAL REQUIREMENTS

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform these functions. Frequent walking throughout manufacturing and warehouse facilities. Ability to stand for extended periods while supporting production operations. Ability to occasionally lift and/or move up to 20 pounds. Ability to work safely in manufacturing environments with varying temperatures and noise levels. Occasional travel may be required based on business needs.

DISCLAIMER

This job description is intended to describe the general nature and level of work performed by employees assigned to this position. It is not intended to be an exhaustive list of all duties, responsibilities, and qualifications required. Management reserves the right to modify responsibilities and requirements as business needs dictate.

Pay:

$69,465.13 - $83,656.92 per year

Work Location:

In person