Senior Engineer, Manufacturing Process Technology, Technology Steward

The Continuous Improvement Engineer is responsible for driving sustainable improvements in manufacturing performance through process optimization, technology advancement, and data-driven decision-making. This role partners closely with Operations, Quality, Maintenance, Engineering, and Supply Chain teams to improve production capacity, yield, cost competitiveness, safety, and product quality. The position leads continuous improvement initiatives, capital projects, digitization efforts, and process innovations that support the site's strategic and operational objectives.

Operational Excellence

• Drive measurable improvements in production throughput, yield, quality, operating costs, and overall process efficiency.
• Analyze manufacturing data to identify improvement opportunities and prioritize initiatives that deliver the greatest business value.
• Utilize Lean Manufacturing, Six Sigma, and Continuous Improvement methodologies to eliminate waste and optimize performance.
• Develop and monitor key performance indicators (KPIs), Overall Equipment Effectiveness (OEE), and financial metrics to assess improvement initiatives.
• Lead root cause investigations and implement sustainable corrective actions using methodologies such as Root Cause Failure Analysis (RCFA), Failure Modes and Effects Analysis (FMEA), and statistical process analysis.
• Support manufacturing teams with technical expertise to resolve process issues and improve operational reliability.

Process and Technology Development

• Identify, evaluate, and implement new technologies, manufacturing processes, automation solutions, and raw materials that improve site performance.
• Lead medium- and long-term improvement programs aligned with business and operational objectives.
• Drive digital transformation initiatives through the application of data analytics, process automation, and advanced manufacturing technologies.
• Develop strategies to debottleneck manufacturing systems and increase production capacity.

Project Leadership

• Develop business cases, including Return on Investment (ROI) analysis, for process improvement and capital investment projects.
• Lead the planning, justification, execution, and startup of capital projects while ensuring compliance with safety, quality, and budget requirements.
• Coordinate cross-functional project teams to achieve project milestones and deliver expected results.

Quality and Customer Focus

• Partner with Quality teams to identify and implement process improvements that strengthen product performance and customer satisfaction.
• Support site quality objectives by reducing internal defects, minimizing customer complaints, and enhancing product consistency.
• Ensure process changes are conducted in accordance with applicable quality systems, ISO standards, and GMP requirements.

Safety, Health, and Environment (SHE)

• Perform work in accordance with safety standards and OSHA 1910.119 Process Safety Management (PSM) requirements.
• Actively participate in safety improvement initiatives, risk assessments, hazard analyses, Management of Change (MOC) activities, and incident investigations.
• Promote a culture of operational discipline, environmental stewardship, and continuous risk reduction.
• Ensure improvement projects prioritize employee safety and environmental compliance.

Leadership and Teamwork

• Provide technical leadership and influence across cross-functional teams to drive continuous improvement initiatives.
• Build strong working relationships with Operations, Maintenance, Quality, Engineering, contractors, and vendors.
• Facilitate collaboration and alignment among stakeholders to achieve project and business objectives.
• Demonstrate company values and contribute to a culture of accountability, engagement, and continuous learning.
• Maintain an active professional development plan to expand technical and leadership capabilities.

Education and Certifications:

Required

• Bachelor's degree in Chemical, Mechanical, Industrial, Manufacturing, or related Engineering discipline.

Preferred

• Six Sigma Green Belt certification or higher.
• Lean Manufacturing certification or demonstrated Lean leadership experience.

Knowledge, Experience, and Skills:

Required

• Minimum of 5 years of manufacturing or production experience.
• Strong analytical and problem-solving capabilities with demonstrated use of data to drive decisions.
• Experience leading process improvement initiatives that deliver measurable operational or financial results.
• Proven ability to lead cross-functional teams and influence without direct authority.
• Experience facilitating RCFA, FMEA, or other structured problem-solving methodologies.
• Knowledge of OSHA 1910.119 Process Safety Management requirements.
• Working knowledge of quality management systems, ISO standards, and GMP practices.
• Strong project management and organizational skills.
• Excellent communication and interpersonal skills.

Preferred

• Experience in film manufacturing, web handling systems, or converting operations.
• Experience with manufacturing automation, process control systems, and industrial digitalization technologies.
• Experience developing business cases and managing capital projects.
• Proficiency in statistical analysis and data visualization tools.

Pay is based on several factors which vary based on position. These include labor markets, work experience, and qualifications.  The expected salary range for this Virgina position is between $120,800 to $205,400.