Continuous Improvement Engineer

Job Description

Job Description

1. Position Purpose

The Lean Engineer is responsible for deploying, sustaining, and continuously improving the Vesuvius Operating System (VOS) at the plant level. The role drives systematic improvement in Safety, Quality, Delivery, Cost, and People (SQDCP) performance through the disciplined application of Lean principles, standard work, and structured problem solving.

The Lean Engineer acts as a VOS champion and change leader, working cross-functionally to eliminate waste, stabilize processes, improve flow, and embed a culture of continuous improvement and accountability aligned with Vesuvius Group standards and strategic objectives.

2. Organizational Alignment

• Reports functionally and operationally to the Site Manager
• Works closely with:
• 1. Production, Maintenance, and Engineering teams
  2. Quality, Supply Chain, and HSE
  3. Plant Leadership Team
  4. Regional and Group Continuous Improvement / VOS resources
• Supports plant-level execution of VOS, operational excellence, and performance improvement initiatives

3. Key Responsibilities

A. Vesuvius Operating System (VOS) Deployment

1. Lead deployment, execution, and sustainment of VOS pillars, tools, and standards at the plant level.

2. Ensure consistent application of VOS routines, including daily management, tiered accountability, and visual performance management.

3. Support leadership in deployment of VPM (Vesuvius Performance Management) system, setting priorities, tracking actions, and closing gaps against SQDCP targets.

4. Act as subject matter expert for VOS tools, methodologies, and behaviors .

B. Continuous Improvement & Waste Elimination

1. Identify and eliminate waste (TIMWOOD) across manufacturing and support processes using Lean methodologies.

2. Facilitate and lead lean workshops, including:

· Kaizen events

· Material and Information Flow Analysis (MIFA) activities

· SMED

· 5S and Visual Management

· Standard Work

3. Drive standardization of processes to reduce variation and improve predictability.

4. Ensure improvements are sustainable and aligned with Vesuvius best practices.

C. Structured Problem Solving & Performance Management

1. Lead and coach teams in structured problem-solving using Vesuvius-standard methodologies, including:

· 8D practical problem solving

· Fishbone and 5Why analysis

2. Support resolution of chronic safety, quality, delivery, cost, and reliability losses.

3. Use data and KPIs to prioritize improvement opportunities and validate results.

4. Coach and support operational teams in the effective use of electronic systems (e.g., VORN) to calculate, monitor, and improve OEE.

5. Drive measurable improvements in OEE, yield, scrap, rework, and throughput.

D. Operations & Process Excellence

1. Partner with production teams to improve process stability, adherence to standard work, and operational discipline.

2. Support optimization of material flow, layout, and production sequencing in alignment with Lean flow principles.

3. Implement pull systems, Kanban, and inventory control solutions where applicable.

4. Support change management for process, layout, and equipment changes.

E. Maintenance, Reliability & TPM Alignment

1. Support deployment of Total Productive Maintenance (TPM) principles in collaboration with Maintenance.

2. Promote operator ownership through basic care and autonomous maintenance activities.

3. Participate in RCFA activities for chronic equipment losses and support sustainable countermeasures.

4. Contribute to improvements in equipment availability, reliability, and OEE.

F. CAPEX, Projects & Business Impact

1. Support development of continuous improvement-related CAPEX and improvement business cases aligned with Vesuvius investment governance.

2. Ensure Lean and VOS principles are embedded in new equipment, process design, and layout changes.

3. Track, validate, and report continuous improvement benefits, including productivity, cost savings, quality improvements, and risk reduction.

4. Support plant Excellence Roadmap development and execution.

G. Safety, Quality & Compliance

1. Ensure Zero Harm is the first priority in all Lean activities.

2. Identify and reduce safety risks through standardization, ergonomics, and process improvements.

3. Partner with Quality to reduce defects, variation, and customer complaints.

4. Support audits, corrective actions, and continuous improvement of management systems.

H. Standardization, Documentation & Capability Building

1. Coach, and support the teams in development and improving:

• Standard Work
• Visual management standards
• MIFA (current and future), Process maps

2. Ensure improvements are documented, standardized, and embedded into daily operations.

3. Train and coach operators, supervisors, and engineers on VOS, Lean tools, and continuous improvement behaviors.

4. Build continuous improvement capability and engagement across the organization to reduce dependency on single individuals.

4. Key Result Areas (KRAs)

1. VOS Maturity: Sustained deployment and adherence to VOS standards and routines.

2. Operational Performance: Measurable improvement in SQDCP metrics.

3. Process Stability: Reduced variation and improved standard work compliance.

4. Culture & Capability: Increased continuous improvement engagement, problem-solving capability, and ownership at all levels.

5. Education & Qualifications

1. Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or related discipline (or equivalent experience).

2. 3–5+ years’ experience in Continuous Improvement or Lean roles within manufacturing

3. Lean / Six Sigma certification (Green Belt or higher) preferred.

4. Experience in a unionized and/or heavy manufacturing environment preferred.

6. Technical Skills & Experience

• Vesuvius Operating System (VOS) or equivalent Lean production systems

• Lean Manufacturing tools and methodologies

• 8D problem solving and RCA

• OEE, KPI development, and performance management

• Material and Information Flow Analysis (MIFA) and process optimization

• PM concepts and cross-functional reliability improvement

• Experience with CMMS, MES, or production data systems preferred

7. Skills & Behaviors

1. Strong shop-floor presence and hands-on execution mindset

2. Credible change agent with high accountability for results

3. Structured, data-driven, and disciplined problem solver

4. Strong facilitation, coaching, and influencing skills

5. Ability to challenge constructively and drive standardization

6. Effective communicator across all organizational levels

7. Role model for Vesuvius values, Zero Harm, and continuous improvement

Vesuvius is a global leader in molten metal flow engineering and technology, primarily serving the global steel and foundry industries. We develop innovative solutions that enable our customers to increase their efficiency and productivity, enhance quality, improve safety and reduce their costs and their environmental impact. Our history spans more than 100 years, we are on six continents with more than 11,000 employees. We value diversity. Sustainability is at the heart of everything we do. We aim to deliver sustainable, profitable growth to provide our shareholders with a superior return on their investment, while providing our employees with a safe workplace where they are recognized, developed and properly rewarded.

Company Description

Vesuvius is a global leader in molten metal flow engineering and technology, primarily serving the global steel and foundry industries. We develop innovative solutions that enable our customers to increase their efficiency and productivity, enhance quality, improve safety and reduce their costs and their environmental impact. Our history spans more than 100 years, we are on six continents with more than 11,000 employees. We value diversity. Sustainability is at the heart of everything we do. We aim to deliver sustainable, profitable growth to provide our shareholders with a superior return on their investment, while providing our employees with a safe workplace where they are recognized, developed and properly rewarded.