Manufacturing Engineer - Continuous Improvement

PURPOSE:

The Manufacturing Engineer is responsible for leading and driving operational excellence initiatives throughout the investment casting manufacturing process. This role focuses on identifying and eliminating waste, improving productivity, reducing costs, enhancing quality, and increasing overall process efficiency through the application of Lean Manufacturing and Continuous Improvement methodologies.

The successful candidate will work cross-functionally with production, quality, maintenance, and engineering teams to implement sustainable improvements that support safety, quality, delivery, and cost objectives. While the primary focus is Continuous Improvement, the role will also provide manufacturing engineering support for process optimization, problem-solving, and new product introduction activities.

ESSENTIAL JOB FUNCTIONS:

• Lead and support continuous improvement initiatives across all areas of the casting operation, including wax, shell, melt, finishing, and support processes.
• Identify inefficiencies, waste, bottlenecks, and variation using Lean Manufacturing principles, process observation, and data analysis.
• Facilitate Kaizen events, Value Stream Mapping activities, and continuous improvement workshops.
• Drive operational excellence initiatives focused on improving safety, quality, delivery, productivity, and cost performance.
• Develop, track, and report key performance indicators (KPIs) to measure process performance and improvement effectiveness.
• Analyze manufacturing processes and implement improvements to increase efficiency, reduce scrap, improve yield, and optimize throughput.
• Lead structured problem-solving efforts using methodologies such as 5-Why, Fishbone (Ishikawa), A3, and Root Cause Analysis (RCA).
• Investigate production and quality issues and implement corrective and preventive actions (CAPAs).
• Take ownership of improvement opportunities and drive implementation through completion, ensuring sustainable results.
• Develop and maintain process documentation, including standard operating procedures (SOPs), work instructions, process flow diagrams, and visual controls.
• Support new product introductions (NPI), process transfers, and manufacturing process transitions.
• Assist with tooling, fixturing, and process optimization activities throughout the manufacturing operation.
• Collaborate with production, quality, maintenance, and engineering teams to develop practical and sustainable solutions.
• Partner with supervisors, operators, and leadership to identify, prioritize, and execute continuous improvement opportunities.
• Conduct data collection, analysis, and reporting to support process improvement and decision-making efforts.
• Provide technical and engineering support to production teams to resolve day-to-day manufacturing challenges.
• Promote and foster a culture of continuous improvement, employee engagement, and accountability throughout the organization.
• Participate in Lean initiatives including 5S, standard work, visual management, and waste reduction programs.
• Communicate project objectives, status updates, results, and recommendations effectively across all levels of the organization.
• Support compliance with safety, quality, and regulatory requirements.
• Perform additional engineering, quality, and operational improvement duties as assigned.

SPECIAL SKILLS AND PHYSICAL REQUIREMENTS:

• Strong analytical, critical thinking, and communication skills.
• Self-motivated, data-driven problem solver with a proven track record of process improvement.
• Ability to work in a heavy manufacturing environment, including lifting materials up to 50 lbs.

With more than 120 operations and approximately 20,000 employees worldwide, Precision Castparts Corp. is the market leader in manufacturing large, complex structural investment castings, airfoil castings, forged components, aerostructures and highly engineered, critical fasteners for aerospace applications. In addition, we are the leading producer of airfoil castings for the industrial gas turbine market. We also manufacture extruded seamless pipe, fittings, and forgings for power generation and oil & gas applications; commercial and military airframe aerostructures; and metal alloys and other materials for the casting and forging industries. With such critical applications, we insist on quality and dependability - not just in the materials and products we make, but in the people we recruit.

PCC is relentless in its dedication to being a high-quality, low-cost and on-time producer; delivering the highest value to its customers while continually pursuing strategic, profitable growth.

In 2016, Berkshire Hathaway, led by Chairman and CEO Warren E. Buffett, acquired Precision Castparts Corp.