SUMMARY

The Continuous Improvement Industrial Engineer is responsible for delivering operational improvements through the strategic deployment of continuous improvement tools and techniques which will result in bottom line, quantified results. Lead the journey of the Lean initiative through the enhancement of the company's long range strategic plan which will drive operational excellence as measured by key performance indicators. This role will also create a Continuous Improvement (CI) culture that drives behaviors of employees to challenge the status quo in order to deliver sustainable results in safety, quality, cost and delivery. Support the business to improve and simplify existing processes and ensure capability of the new ones to drive reliability, predictability and efficiency while making the best use of available resources using continuous improvement methodologies through manufacturing, supply chain and commercial operations.

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Create a lean and continuous improvement roadmap that includes a comprehensive analysis and prioritization of key opportunities for the region. Include and engage cross functional members at all levels of the organization as well as execute initiatives that will drive sustainable results.
• Work closely with the Plant Management team to drive and foster a cultural transformation through the business by building effective matrix teams and driving involvement and talent multiplication to deliver successful productivity, cost reduction and/or quality improvement initiatives.
• Develop and facilitate a wide variety of improvement initiatives, workshops and projects designed to improve throughput time, flexibility, quality and value utilizing lean techniques such as Kaizen, Six Sigma, Value Stream Mapping (VSM), Single Minute Exchange of Die (SMED), 8-D, Problem Solving and Value Analysis which result in significant efficiency improvements for the facility.
• Train and coach the Plant Management team in MAHLE Shop Floor Management leadership behaviors, leadership instruments and leadership tasks.
• Motivate, train, involve and develop Managers, Supervisors, Team Leaders and associates on Continuous Improvement (CI) techniques; including one-on-one mentoring as needed.
• Develop training materials and effectively deliver those materials in a team environment to ensure employees throughout the facility are trained in CI concepts and philosophy.
• Create a culture which supports disciplined & systematic process management; data driven decision making; continuous improvement aligned with established strategy & objectives.  Participate in integrated process development for new program launches and approve process design per PDP requirements.
• Serve as a leader of change and innovation.  Challenge status quo, effectively influence others (at all levels of the organization) to embrace change, overcome resistance and seek out outstanding ideas and implement.
• Establish measurement systems where needed to identify opportunities and to quantify implemented improvements.
• Ensure the sharing and driving of best practices and lessons learned (internal / external). Deliver sustainable cultural and behavioral changes across the business to build a CI Lean culture including support functions, through coaching, mentoring and influencing employees, business team leaders, and global lean professionals.
• Conduct studies in cost, quality, productivity, flow, value stream mapping and root cause analysis.
• Conduct operational audits to identify areas of opportunity.
• Work in conjunction with Purchasing to conduct supplier visits for CI workshops where required.
• Follow up and audit event progress to ensure results are achieved and sustained.
• Record parameters, production processes, tracking & documentation in database
• Analyze manufacturing efficiency & conduct problem solving & corrective action
• PCP adherence & complete all required documentation
• Provide cost analysis justifications for capital investments (PAR’s)
• Sign off equipment at integrators (@ costed cycle times)
• Support quote team activity and R&D activity on the acquisition team
• Other duties as assigned.

EDUCATION and/or EXPERIENCE

• Electrical / Mechanical / Plastic Processing Engineering Degree or equivalent combination of experience
• Minimum 3 years of experience with automotive injection molding, controls,  processing & assembly related equipment

• 7-10 years of automotive process engineering experience is required; 5+ years of Continuous Improvement experience is strongly preferred.
• Six Sigma Greenbelt or Blackbelt Certification is strongly preferred.
• Proven understanding & successful application of Continuous Improvement tools and methodologies including Lean and Six Sigma.
• Ability to handle projects with multiple workstreams, with proven leadership success over a wide variety of business problems.
• Proven & effective facilitation, leadership, mentoring, and training skills.
• Ability to provide decisive leadership and team facilitation in the face of adversity - define tasks clearly, identify and coordinate resources, and execute a go-forward plan.
• Ability to define goals, metrics, and levels of success for internal/external customers.
• Proven planning abilities, including successful execution of such plans.
• Proven execution of change management within an organization.

   Do you have any questions?
     
   DAVE.DULLACK@MAHLE.COM 

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