Continuous Improvement Engineer
About Us:
At Tomball Controls, we specialize in manufacturing custom fuel tanks, custom sound attenuated enclosures, and access platforms for emergency power generators.
We are proud to serve clients across various industries, providing them with high-quality power packaging solutions to meet their specific requirements. With years of experience among our team members and a commitment to excellence, we have built a reputation for delivering reliable, durable products on time and within budget.
Job Description:
The Continuous Improvement (CI) Engineer drives Lean manufacturing, Kaizen-based improvements, process optimization, and NPI readiness within a metal-mechanical manufacturing environment for datacenter enclosures. This role focuses on enhancing safety quality, delivery, and cost through structured Kaizen events, process capability improvements, and strong cross-functional collaboration.
Key Responsibilities:
- Lead and facilitate Kaizen events (rapid improvement workshops) across fabrication, welding, machining, painting, assembly, and test operations.
- Deploy Lean tools such as 5S, Value Stream Mapping (VSM), SMED, TPM, Standard Work, Visual Management, and Kanban, establish and sustain Daily Management Systems, tier meetings, and visual KPI boards.
- Partner closely with NPI Engineering for enclosures, tanks platforms and structural components; support First Article Inspection (FAI) for NPIs.
- Conduct time studies, line balancing, ergonomic assessments, and optimize factory layouts.
- Support and lead PFMEA, Control Plans, process flow diagrams, and implement poka-yoke (error-proofing) solutions.
- Drive cultural adoption of continuous improvement and actively engage employees in Kaizen activities.
- Collaborate with Process Engineering to enhance process stability, capability, and repeatability.
- Analyze scrap, rework and defects; lead root-cause analysis using 5-Why, Fishbone, PDCA and DMAIC methodologies.
- Create and release routings, validate BOMs, define tooling requirements, and develop work instructions for new products.