Continuous Improvement / Lean Engineer

Job Description

Main job objective - Mission:

· Lean/Continuous improvement (CI) is an essential part of the BD strategy.

· The Lean/CI Engineer will drive waste reduction through the application of Value Stream Management and appropriate Lean manufacturing philosophies, tools and methodologies (i.e. 5S, Kaizen, SMED, Daily Performance Management, A3, Standardized Work, etc.).

· The Lean/CI Engineer assists the local management team and/or Lean/CI Manager with implementing and sustaining the Lean Management execution system. Also will support the QMS sustainability as internal auditor.

· The Lean/CI Engineer implements Execution System -Leader Standard Work - and relevant Lean tools within the functional locations of responsibility, working in close collaboration with the Lean/CI Manager, the local management team and operational line management.

· Lean/CI Engineer actively supports the development of the Continuous Improvement based performance culture in BD following the CI assessment criteria.

Work territory - Job dimension:

- This position is based in Winston-Salem, North Carolina (United States).

Essential Functions and Key Result Areas:

· Coach operations and teams to apply Lean materials flow principles to enhance material flow.

· Train and support Continuous Improvement events with departments to determine and eliminate waste.

· Engage in establishing SMART goals for Lean execution and Value stream improvement.

· Lead cross-functional teams to streamline the material movement process & eliminate non-value added (Muda).

· Implement KPI’s for production department to help measure Managing Daily Improvement. Establish and maintain appropriate KPI’s to check actual conditions vs. target, as well as determine and measure the impact of implemented improvements.

· Apply appropriate Lean tools to analyze the actual condition and determine underlying constraints preventing improvement.

· Identify opportunities for improvement and prioritize by impact to operations within priorities set by management.

· Determine and implement appropriate countermeasures to drive improvement i.e. standardized work, poke yokes, changes to work area, layout changes, etc.

· Foster an environment of continuous improvement through engagement, training, and support at all levels of the organization.

· Prepare appropriate documents to report progress on projects at management meetings, as assigned.

· Present and teach information regarding continuous improvement during NA group or plant-wide meetings.

· Benchmark other facilities with similar processes and apply best practices at processes.

· Participate in QMS Internal Audits as auditee and as auditor.

Other duties as assigned.

Main Responsibilities

1. In collaboration with Department manager and other leaders, lead and drive sustainable purposeful and meaningful leader standard work and CI Governance including: Gemba Walks for 5S, Performance Management, and Safety.

2. Daily, Weekly and monthly CI meetings and reviews at the department level.

3. In collaboration with Department Manager and other leaders own the sustainment and improvement of the Daily Performance Management system and application of BD standard Lean tool set.

4. Hands on support of the implementation and sustainment of the BD overall CI strategy and chosen methodologies.

5. Work closely with Leaders in the business to evaluate and challenge the status quo, identifying and executing functional and cross-functional improvement opportunities.

6. Works closely with, and receives program support and direction from Lean/CI Manager/Director.

7. Ensure CI Maturity assessment requirements are met for DPM and broader CI roadmap (5S+1, Standard Work, Pull systems, Quality assurance, Improvement board, etcetera).

8. Conducts root cause analysis related to Safety, Environment, Quality, Delivery, Cost, Inventory (SEQDCI) KPIs using the adequate tools of a set as defined by BD and its investors (RCCM, A3, 8D, 5Why, TTI, Project Charter etc).

9. Plays an active and organizing role in productive Kaizen events in their locations.

10. Creates and improves the necessary workflow schemes for the process development and controls within the scope of the Quality Management System.

11. Works based on principles of Lean Manufacturing and Continuous Improvement.

12. Lead data collection on floor, lead A3 workshops with team, coach departments as needed, attend DPM (Daily Performance Management Tier 1 and Tier 2 meetings) and help the teams with floor Gemba, problem solving and find root causes to reach proper corrective actions. Execute corrective actions with team and close projects providing savings.

13. Coach and mentor groups of hourly team practitioners in department areas of responsibility to increase their CI-lean development and assist them to obtain their Internal certifications.

14. Leads, schedules and ensures the 5S+1 audit program is executed, and corrective actions are implemented by working closely with the department leadership and lean practitioners meeting target maturity levels.

15. Manages completed idea program tools and engages employees in the department areas of responsibility ensuring coaching, mentorship and execution of ideas for improvement.

Company Description

BekaertDeslee is the global market leader in the development and production of mattress fabrics and mattress covers. Over six hundred million people worldwide are sleeping on BekaertDeslee fabrics & covers every night. BekaertDeslee USA (BDUS) is a production and distribution center for mattress fabrics and covers operations in US with a revenue of approximately 140 million USD.