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Sr Process Improvement Engineer - Capital Projects

Louisville, KY, United States  |  Engineering  |  ID: REQ-14140


Job Location

USA, Louisville, KY

Job Posting Title

Sr Process Improvement Engineer - Capital Projects

The Challenge

As the Senior Process Improvement Engineer, you will manage stamping and link line equipment and process effectiveness within a Stamping Metal Fabrication area. You will troubleshoot process issues and drive operational improvements, through effective problem solving and corrective action implementation, to continuously improve safety, quality, delivery, cost & morale.

What you will Do


  • Own all equipment and tooling in the production area, from Advanced Mfg Engineer (AME) sign-off and forward.
  • Serve as the primary troubleshooting resource for the process in the plant. Consult with maintenance staff on equipment repair.
  • Monitor and work to improve Overall Equipment Efficiency (OEE) in the area.
  • Recommend equipment and tooling for existing process; consult and sign-off on new purchases when applicable.
  • Consult with Maintenance Business Leader on the maintenance action item list and/or priorities for the area.
  • Monitor and ensure the calibration of all equipment.
  • Provide feedback on equipment specifications (Gray Book content) based upon best practices and lessons learned.
  • Partner with plant TPM and AME teams to implement and maintain a robust TPM plan for all equipment.


  • Improve and direct Preventive Maintenance plan for assigned area.
  • Root cause based troubleshooting, schematic reading, PLC's and ladder logic programming, Siemens Step 7, Allen Bradley, GE Proficy, Wintriss, variable frequency drives, Ethernet communications, Vision Systems and safety procedures such as Lock Out -Tag Out.
  • Support all plant priorities in the areas of EHS, Schedule Attainment, Spoilage & Yield, Labor & Overtime, Productivity, Spare Parts cost controls and Lean Manufacturing.
  • Execute routine equipment purchases, to include presenting justification for capital expenses or process improvements, design and specification of equipment and standardization of equipment within manufacturing methods and safety requirements.
  • Provide training and aid in trouble-shooting and downtime response in specified area of expertise.
  • Steer up-time and equipment reliability improvements through simplification activities.
  • Develop and guide cross functional projects with other departments and suppliers to make entire supply chain more robust, driving OEE.


  • Engage in and lead problem-solving for production area. Lead root cause identification of problems, implement appropriate countermeasures, and share across as best practice (yokoten).
  • Partner with Plant Operations personnel to promote and support a team that reacts aggressively to factory inefficiencies. 
  • Work cross-functionally with Team Leaders, Kaizen Promotion Officers, Business Leaders and Lean resources on short term and long term improvement initiatives. 
  • Implement related countermeasures on manufacturing line(s) (kaizen activities). 
  • Implement Poka-Yoke work methods, and develop workstation aids to assist in operator job performance. 
  • Support the Team and Business Leaders in the planning and execution of work area rebalancing utilizing Yamazumi charts. 


  • Support Business Leader by identifying and implementing safety-related corrective actions and improvements for the area. 
  • Assist with action item completion for the area's safety action item list, including corrective actions from near misses, accident reports & ergo assessments.


  • Coordinate with AME on equipment purchases & qualification. 
  • Provide the "voice of the plant", giving feedback on lessons learned and plant preferences. 
  • Review product prototypes and concepts for manufacturability. 
  • Provide feedback to the NPI team on capacity, impact on operator and process stability/sustainability. 
  • Interface with vendors and OEM suppliers, along with Facilities Engineer, to learn maintenance requirements and equipment troubleshooting. Distribute information and knowledge. 
  • Update manufacturing control documents, floor & workstation layouts. Work with Team Leaders on Standard Work and Job Instruction creation.

What you need to Succeed

Minimum Qualifications:

  • Minimum of Bachelor’s Degree required (or equivalent experience.)
  • Minimum of 5 years’ relevant maintenance, robotic automation and continuous improvement work experience in a stamping environment.
  • Leadership and project management experience in manufacturing operations, preferably unionized operations.

Preferred Qualifications:

  • Minimum of Bachelor’s Degree with technical degree (or equivalent technical experience.)
  • Knowledge of Appliances manufacturing processes.
  • 10 plus years experience in Controls, PMs, mechanical, hydraulic, pneumatics and welding techniques.
  • Experience and training in LEAN manufacturing practices.
  • Six Sigma certification or Kaizen, 5S, TPS, or similar LEAN certifications.
  • Quality Leadership experience.
  • Program Management skills.

Position Requirements

  • Demonstrated experience in troubleshooting high volume Stamping presses and metal fabrication equipment.
  • Efficient in PLC troubleshooting and ladder logic.
  • Strong project management and analytical/problem solving skills with demonstrated ability to scope and analyze cross-functional problems to generate/implement solutions.
  • Ability to adapt to and juggle changing and competing priorities.
  • Early and/or late hours and occasional weekends often required to work around the manufacturing schedule / timing.
  • Ability to work collaboratively in a cross-functional team environment with both hourly and salary personnel to meet the needs of operators, the program and the business.

Working Conditions:

  • Working conditions are normal for both an office and manufacturing environment. 
  • Work may involve lifting of materials and product up to 25 pounds. 
  • Working in the manufacturing environment requires the use of safety equipment to include but not limited to: safety glasses, hearing protection, gloves, work shoes/boots. 
  • Work may require occasional weekend and/or evening work.
  • Travel may be required for domestic and/or international travel to other sites/plants, etc.

GE Appliances is an Equal Opportunity Employer.  Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.



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