Sr. CI Engineer

The Senior Continuous Improvement (CI) Engineer drives operational excellence by identifying improvement opportunities, leading process improvement initiatives, and supporting teams in implementing sustainable solutions. This role uses Lean, Six Sigma, and problem-solving methodologies to enhance efficiency, reduce waste, and improve quality across the organization. This roll will be based out of our Janesville, WI, or Union, OH facilities. Up to 50% travel across sites is anticipated.

ESSENTIAL DUTIES & RESPONSIBILITIES

Process Improvement & Optimization Identify and improve operational inefficiencies across departments using data-driven methods. Lead cross-functional Kaizen events, workshops, and CI projects. Facilitate root cause analysis (RCA) using tools such as 5 Whys, Fishbone diagrams, and FMEA. Data Analysis & Reporting Collect, interpret, and visualize data to uncover trends and improvement opportunities. Maintain KPI's and dashboards to track performance related to SQDC. Report progress and outcomes to leadership and stakeholders. Lean & Six Sigma Integration Apply Lean methodologies to reduce waste, improve flow, and standardize processes. Support Six Sigma projects by contributing analysis, documentation, and facilitation. Maintain CI tools, templates, and standard practices for the organization. Change Management & Training Support teams through change by communicating benefits, risks, and impacts of CI initiatives. Provide coaching, training, and guidance on CI tools and methodologies. Foster a culture of continual improvement and employee engagement.

QUALIFICATIONS

Required Bachelor's degree in Business Management, Engineering, Operations, or related field. 10 years of experience in Manufacturing, with 5+ years working in a Continuous Improvement capacity. Experience with Lean, Six Sigma, or continuous improvement methodologies. Green Belt or higher preferred. Possess a Hands on, "go to Gemba" approach to Continuous Improvement implementation. Strong analytical skills with the ability to translate data into insights. Excellent facilitation, communication, and cross-functional collaboration skills. Preferred Experience with metal fabrication, welding, or assembly processes relevant to United Alloy's operations. Knowledge of advanced manufacturing technologies (e.g., automation, IoT, Industry 4.0). Familiarity with TPM (Total Productive Maintenance) and OEE optimization. Experience with project management methodologies (e.g., Agile, PMP). Lean Six Sigma Green Belt or higher certification. Proficiency with CI software, data visualization tools (Power BI, Tableau), or statistical analysis tools. Key Competencies Strong problem-solving mindset. Ability to influence without authority and collaborate across teams. Detail-driven with a focus on measurable results. Adaptable, curious, and committed to ongoing learning and improvement. 12 Expected Behaviors of Actively Engaged Person - 100% Responsible, Trustworthy, Team Player, Clear Communicator, Empathy, Humility, Emotional Self-Control, Resolves Conflict Directly, Positive Attitude, Respects Others, Problem Solver, and Agile. Working Conditions Office and production floor environment. Full-time role requiring regular presence on the manufacturing shop floor at one of United Alloy's facilities. Up to 50% travel to other United Alloy facilities to support Lean initiatives and ensure consistency across sites.