Continuous Improvement Engineer

• 2.6 7313 William Barry Boulevard, North Syracuse, NY 13212 $85,000 - $110,000 a year Apply with Indeed Position Summary The Continuous Improvement Engineer is responsible for identifying and implementing improvements that increase productivity, quality, delivery performance, capacity, and cost competitiveness within printed circuit board assembly (PCBA) manufacturing operations. This position works closely with Production, Manufacturing Engineering, Quality, Materials, Supply Chain, and Maintenance to improve processes from material kitting through final assembly and test. The role applies Lean Manufacturing, Six Sigma, data analysis, root-cause analysis, and problem-solving methods to reduce waste, improve flow, increase first-pass yield, lower cost, and strengthen manufacturing performance. Key Responsibilities Analyze production processes, workflows, labor utilization, downtime, scrap, rework, FPY, capacity, cost, and delivery performance. Identify bottlenecks and improvement opportunities across SMT, through-hole, hand-placed assembly, wave solder, conformal coating, inspection, test, and final assembly operations. Lead continuous improvement projects using Lean, Six Sigma, Kaizen, 5S, value-stream mapping, and standard work. Improve line balancing, production flow, material presentation, workstation layout, changeover time, and labor efficiency. Conduct time-studies and develop accurate labor standards and process capacity requirements. Lead root-cause investigations using tools such as 5-Why, fishbone diagrams, Pareto analysis, and statistical analysis. Partner with Quality to reduce defects, solder-related issues, component placement errors, escapes, scrap, and rework. Improve first-pass yield, production yield, on-time delivery, schedule attainment, and overall equipment effectiveness. Support the development and maintaining of standard work instructions, visual controls, process documentation, and performance dashboards. Support PFMEA, control plans, process audits, and corrective/preventive action activities. Evaluate and implement improvements involving equipment, tooling, fixtures, automation, software, and manufacturing methods. Support new product stage gate introductions, line transfers, process validation, and engineering change implementation. Track project benefits, including labor savings, capacity gains, scrap reduction, productivity improvements, and cost avoidance. Train employees and supervisors on improved processes, standard work, Lean tools, and problem-solving methods. Promote employee involvement through structured Kaizen and improvement activities. Ensure improvements comply with applicable customer, quality, safety, and regulatory requirements. Required Qualifications Bachelor's degree in Industrial Engineering, Manufacturing Technology, Mechanical Engineering, Electrical Engineering, or a related field. Experience in electronics, PCBA, contract manufacturing, or high-mix manufacturing environments. Knowledge of Lean Manufacturing and continuous improvement methodologies. Experience with process mapping, time studies, capacity analysis, and root-cause problem solving. Strong analytical and data interpretation skills. Ability to read manufacturing documentation, assembly drawings, bills of material, and process specifications. Proficiency with Microsoft Excel/Power Point, and experience developing reports, dashboards, or performance metrics. Strong communication, project management, and cross-functional collaboration skills. Preferred Qualifications Lean Six Sigma Green Belt or Black Belt certification. Experience with SMT placement equipment, soldering processes, AOI, SPI, X-ray, ICT, functional test, or final assembly. Experience with ERP, MES, production scheduling, or manufacturing data systems. Knowledge of IPC and related PCBA workmanship standards. Experience with statistical process control, capability studies, and DOE. Experience with automation, robotics, or error-proofing systems. Project management experience in a manufacturing environment. Key Performance Indicators First-pass yield and production yield improvement. Scrap and rework reduction. Labor productivity and units per labor hour. Schedule attainment and on-time delivery. Overall equipment effectiveness. Downtime and changeover-time reduction. Capacity improvement and bottleneck elimination. Cost savings and cost avoidance. Kaizen implementation rate. Corrective-action completion and effectiveness. Employee participation in improvement activities. Core Competencies Continuous improvement mindset Data-driven decision making Structured problem solving Lean Manufacturing knowledge PCBA process knowledge Project leadership Communication and collaboration Attention to detail Change management Ability to influence without direct authority Physical and Work Requirements Ability to work in a manufacturing environment and regularly visit production areas. Ability to stand, walk, and inspect processes on the production floor. Ability to occasionally lift or handle materials, tools, or equipment as required. Must follow all safety, environmental, and ESD requirements applicable to the facility.