SR Cost Industrial Engineer
Description
Live Comfortably is searching for a Sr. Cost Industrial Engineer to be located in our Martinsville, Virgina location. The person in this role will be required to travel up to 70% of the time and oversee up to 4 FT associates.
OVERVIEW:
The Senior Cost Industrial Engineer (IE) serves as a key link between manufacturing operations, process optimization, financial cost management, and people leadership. This role analyzes labor, materials, equipment, and workflows to establish standard costs, identify inefficiencies, reduce waste, and lead cost-reduction initiatives that drive operational performance.
Responsible for evaluating, developing, and optimizing manufacturing processes, the Senior Cost IE works to improve productivity, quality, safety, and overall cost efficiency. Partnering closely with Production, Quality, Maintenance, Supply Chain, Finance, and Operations teams, this position identifies opportunities for continuous improvement and implements sustainable solutions that support operational excellence.
The Senior Cost IE directly leads a team of approximately 3-4 supporting staff members, providing coaching, development, performance management, and strategic direction. This role is responsible for building a high-performing team, establishing clear expectations, fostering accountability, and developing talent to meet both current and future business needs.
The Senior Cost IE leads projects focused on process improvement through Lean manufacturing principles, automation, and continuous improvement methodologies. By leveraging data analysis, engineering expertise, and financial insight, this role improves product consistency, increases throughput, enhances quality, and optimizes manufacturing costs in a fast-paced environment.
This position plays a critical role in ensuring Live Comfortably remains an industry leader through world-class operations, high-performance standards, and strong associate engagement. The Senior Cost IE recommends, implements, and supports best-in-class operational practices, policies, and procedures while fostering a culture of accountability, collaboration, and continuous improvement.
Success in this role requires a passion for building relationships, developing people, and partnering across all levels of the organization. The ideal candidate effectively communicates with associates ranging from entry-level team members to senior executive leadership and works collaboratively with local and corporate teams to drive business results and create a winning organization.
Role Overview & Core Responsibilities
- Standard Cost Development: Establish and update standard costs for products, including Labor Standards, Machine Rates, and Bill of Materials (BOM) accuracy.
- Variance Analysis: Investigate and report on manufacturing variances (labor efficiency, material usage/yield, and purchase price variance).
- Process & Cost Optimization: Conduct time studies, line-balancing, and value stream mapping to lower unit production costs without sacrificing quality.
- Capital Expenditure & ROI Analysis: Evaluate equipment purchases, automation upgrades, and layout changes using payback periods, net present value (NPV), and internal rate of return
- Cross-Functional Collaboration: Partner with plant management, finance, production control, and supply chain to align operational targets with budgetary constraints.
- Continuous Improvement (Lean/Six Sigma): Lead cost-reduction workshops, waste-elimination initiatives, and lean manufacturing events.
- People Leadership & Team Development: Lead, coach, and develop a team of approximately 3-4 direct reports by setting clear expectations, driving accountability, supporting career development, managing performance, and fostering a culture of engagement, collaboration, and continuous improvement.
ESSENTIAL DUTIES AND RESPONSIBILITIES:
- Lead, coach, develop, and manage a team of approximately 3-4 direct reports, including performance management, talent development, succession planning, and associate engagement.
- Establish team objectives and priorities that align with plant, operational, and business goals.
- Resolve technical and process-related issues that impact manufacturing performance, product quality, and reproducibility.
- Analyze production data and key performance indicators (KPIs) to identify trends, risks, and opportunities for improvement.
- Support equipment design, installation, validation, maintenance, and capital project implementation.
- Collaborate with cross-functional teams to improve manufacturability, product quality, and operational performance.
- Evaluate product designs and manufacturing processes to improve manufacturability, efficiency, and product quality.
- Maintain engineering documentation, including process flows, PFMEAs, control plans, work instructions, and standard operating procedures.
- Develop and implement workstations, process, and layout improvements that enhance safety, quality, ergonomics, and productivity.
- Recommend and support policies, procedures, and best practices that promote operational excellence.
- Drive a culture of accountability, safety, continuous improvement, and operational excellence through effective leadership and communication.
- Conduct regular coaching, feedback, and development discussions to build technical capability and leadership bench strength
- Model company values and leadership expectations while building strong partnerships across all levels of the organization.
- Perform other duties as assigned.
REQUIREMENTS, SKILLS AND QUALIFICATIONS
- Bachelor’s degree in Industrial Engineering or another similar Engineering field, Masters preferred.
- 10+ years manufacturing experience, textile or similar industry a plus.
- Proficiency in ERP systems (NetSuite, Scale).
- Advanced data modeling and spreadsheet capabilities (Access, Excel, SQL, Power BI)
- Track record of successfully working within and across functional teams, driving change, and implementing new processes to significantly improve process efficiencies in manufacturing.
- Demonstrated leadership experience with a proven ability to lead, coach, develop, and motivate technical or operational teams in a manufacturing environment.
- Ability to work with different technology to provide a solution that produces the required result in the most efficient way possible.
- Lean manufacturing/Six Sigma certification -Green Belt as a minimum, Black Belt Certification is preferred-
- Strong Microsoft Office
- Ability to communicate with employees at all levels of the organization.
- Capable of influencing other people to implement changes to processes.
Competencies necessary to be successful in role:
- Strong Analytical Skills
- Excellent Verbal and Written Communication
- Problem Solving and Solution Execution
- Collaboration and Relationship Building
- Leadership and People Development
- Team Building and Associate Engagement
- Ability to Work Effectively Under Pressure
- Safety Mindset
- Project Management
- Organization and Time Management
- Continuous Improvement Mindset
- Strategic Thinking
- Adaptability and Change Management
- Influencing and Stakeholder Management
- Data-Driven Decision Making
SUPERVISORY RESPONSIBILITIES
- 3-4 Direct Reports
LOCATION
- Assigned to multiple manufacturing facilities.
TRAVEL
- Frequently, up to 70%
PHYSICAL DEMANDS
To perform the essential functions of this position successfully, an individual must be able to meet the following physical demands with or without reasonable accommodation:
- Ability to perform the essential functions of the position in a manufacturing, warehouse, and office environment.
- Ability to move throughout manufacturing and warehouse facilities to observe operations, conduct process evaluations, and support project implementation.
- Ability to remain stationary and operate a computer and other standard office equipment for extended periods.
- Ability to communicate effectively with associates, leadership, vendors, and other stakeholders.
- Ability to observe and assess manufacturing processes, equipment operation, and workplace conditions.
- Ability to occasionally position oneself, traverse production areas, and access equipment or workstations as needed to perform job responsibilities.
- Ability to occasionally move materials, tools, or equipment consistent with business needs.
- Ability to wear required personal protective equipment (PPE) and comply with all safety requirements when working in operational areas.
- Ability to travel between facilities and other business locations as required.
Reasonable accommodations may be made to enable qualified individuals with disabilities to perform the essential functions of the position.
Work Environment
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. EEO/Vet Disabled
- Regular interaction with production equipment, machinery, forklifts, and other industrial material-handling equipment is required.
- Associates may be exposed to varying noise levels, including designated areas where hearing protection is required.
- Some manufacturing and warehouse areas are not climate controlled and may involve exposure to varying temperatures, including heat and cold.
- Exposure to dust, airborne particles, and other conditions commonly associated with manufacturing, storage, and distribution environments may occur.
- Required personal protective equipment (PPE), including safety glasses, hearing protection, appropriate footwear, and other safety equipment, must be worn as designated.
- Associates are expected to follow all safety policies, procedures, and regulatory requirements while working in operational areas.
The Company’s job descriptions, to include this one, are not intended to be a complete detailed account of all expected/anticipated activities. We operate in a fast-moving and competitive global environment and therefore need Associates to be flexible and assist with other duties when needed to meet those requirements.