Lean Engineer

About the Role

SMC Ltd. is seeking a Lean Leader for its Molding department at the Devens, MA location. This role is responsible for the effective implementation and management of lean tools, systems, and principles across site operations. The position requires interaction with all levels of personnel throughout the manufacturing facility in the development and deployment of lean methodologies, providing hands-on expertise, leadership, assistance, mentorship, and recommendations.

Key Responsibilities

• Lead initiatives to improve efficiency, quality, and productivity across all operational aspects.
• Implement and supervise strategies and processes to promote a culture of continuous improvement.
• Strategy Development:
• Collaborate with senior management to implement operational excellence strategies.
• Implement continuous improvement strategies using Lean methodologies, Six Sigma, and other operational excellence tools.
• Foster a culture of continuous improvement at all organizational levels.
• Project Management:
• Lead continuous improvement projects in all functional areas, identifying optimization opportunities and coordinating cross-functional teams.
• Methodologies Implementation / Innovation and Continuous Improvement:
• Apply methodologies such as Lean Manufacturing, Six Sigma, and Kaizen to eliminate waste, reduce variability, and improve operational efficiency.
• Identify and implement new technologies and methods to improve productivity and operational efficiency.
• Facilitate Kaizen sessions, Gemba walk events, and other improvement dynamics.
• Coordinate internal audits of processes and management systems.
• Data Analysis:
• Use analytical tools to collect, analyze, and present data on operational performance, identifying trends and areas for improvement.
• Prepare and submit detailed reports on operational performance and improvement project results.
• Change Management:
• Facilitate the adoption of organizational and cultural changes, providing training, communication, and support.
• Talent Development:
• Oversee and develop the operational excellence team.
• Execute training programs for employees in continuous improvement methodologies and operational excellence.
• Interdepartmental Relations:
• Collaborate closely with other departments to identify improvement opportunities and ensure effective integration of engineering initiatives.
• Establish and maintain effective relationships with customers, suppliers, and other key stakeholders.
• Lead and implement Lean and continuous improvement initiatives across manufacturing processes.
• Conduct value stream mapping, time studies, and process flow analyses to identify and eliminate non-value-added activities.
• Facilitate Kaizen events, 5S programs, and root cause problem-solving sessions.
• Develop and maintain standardized work, work instructions, and visual management systems.
• Collaborate with cross-functional teams (Production, Quality, Maintenance, Supply Chain, and Engineering) to drive process optimization and cost reduction.
• Monitor and report on key performance indicators (KPIs) such as OEE, yield, cycle time, and defect rates.
• Support new product introduction (NPI) by ensuring efficient production layout, material flow, and equipment utilization.
• Train and coach employees on Lean principles and continuous improvement culture.
• Participate in safety and quality improvement initiatives.
• Analyze production data to identify trends, root causes, and improvement opportunities.

Requirements & Tech Stack

• Proven experience in implementing Lean Manufacturing tools such as:
• 5S, Kaizen, SMED, Kanban, Poka-Yoke
• Value Stream Mapping (VSM)
• Standard Work and Visual Management
• Root Cause Analysis (RCA) and Problem-Solving (A3, PDCA)
• Knowledge of Six Sigma methodology (Green Belt or higher preferred).
• Strong analytical, project management, and facilitation skills.
• Excellent communication and interpersonal abilities.
• Proficiency in tools such as MS Office, AutoCAD, and statistical analysis software (e.g., Minitab).

Qualifications

• Applicable B.S. degree or equivalent experience successfully applying lean manufacturing techniques in manufacturing and transactional processes.
• Demonstrates the ability to lead change and members of the organization.
• Demonstrates the ability to lead and motivate teams to achieve business goals.
• Bachelor's degree in engineering or related field preferred.
• Performance mindset and a passion to improve people, processes, and tools.
• Experience applying lean tools, systems, and principles.
• Excellent communication.