Continuous Improvement Engineer bei Cayuga Milk Ingredients, LLC

Description

Position Title:  Continuous Improvement Engineer 

Reports To: Director of Plant Engineering

FLSA Status: Exempt

Job Grade: 9

Pay Range: $94,000-$134,000

Position Overview:

The Continuous Improvement (CI) Engineer is responsible for identifying, analyzing, and driving the reduction of process losses and inefficiencies across all production areas. This role combines data-driven engineering with Lean Six Sigma methodologies to optimize performance, reduce waste, enhance quality, and improve overall operational reliability. The CI Engineer partners cross-functionally to design and implement sustainable systems that promote continuous learning, process discipline, and long-term cost savings.

Key Responsibilities

Process Loss Reduction & Data Analysis

• Lead data collection, analysis, and model development to identify and quantify losses throughout the facility (mass balance, product yields, line efficiencies, downtime, waste, etc.).
• Partner with Finance to ensure accurate accounting and financial impact of losses.
• Design, implement, and maintain tracking systems and dashboards for product loss, scrap, and process performance data.
• Lead root cause analysis and corrective/preventive action plans to eliminate recurring losses.
• Conduct daily and weekly loss reviews; communicate trends and recommend improvements.

Continuous Improvement Leadership

• Lead and support site-wide CI initiatives across safety, quality, productivity, and cost optimization.
• Apply Lean Six Sigma and structured problem-solving techniques to identify and eliminate process waste.
• Develop and coach standard work, time studies, cycle time optimization, SMED, and line balance analysis.
• Establish and sustain daily management systems, tiered meetings, and KPI routines to reinforce accountability and performance improvement.
• Act as a change agent by coaching and mentoring operations, maintenance, and quality teams to build CI capability.

Systems, Process & Equipment Optimization

• Collaborate with engineering, production, and maintenance to ensure systems (CIP, fillers, processing, filtration, etc.) are optimized to minimize product and utility losses.
• Verify that high-solids streams are properly managed and that drain losses are minimized.
• Support implementation of automation and digital transformation projects.
• Train and mentor employees on continuous improvement principles.
• Support initiatives in energy and water consumption reduction.
• Recommend and support process control improvements through updates to procedures, drawings, and automation logic (experience with CAD, SolidWorks, or PLCs a plus).
• Lead implementation of new CI and operational excellence workflows, tools, and performance routines.

Cross-Functional Collaboration

• Partner closely with Quality, Finance, Engineering, and Production to align improvement priorities with business goals.
• Support and facilitate kaizen events and project-based initiatives focused on yield improvement and waste reduction.
• Communicate progress, lessons learned, and success stories to foster a culture of engagement and continuous learning.

Skills & Qualifications Required

• Bachelor’s Degree in Engineering (Chemical, Mechanical, Industrial, or related technical discipline).
• 3+ years of experience in food, beverage, or chemical process manufacturing.
• Proven track record of leading cross-functional projects focused on process optimization and waste reduction.
• Strong analytical, statistical, and problem-solving skills; data-driven mindset.
• Develop, track, and report key production metrics (OEE, yield, downtime, rework, etc.).
• Working knowledge of process flow, fluid mass balance, and manufacturing systems.
• Excellent interpersonal, communication, and presentation skills.
• Demonstrated ability to manage multiple projects and priorities in a fast-paced environment.
• Strong financial acumen to translate process improvements into measurable business impact.
• Proficiency in Excel, Power BI, and process mapping tools (Visio, Minitab, etc.)
• Experience with ERP and production data systems.

Skills & Qualifications Preferred

• Lean Six Sigma Green or Black Belt certification.
• Experience in aseptic/dairy processing including UHT, homogenization, separation, filtration, and CIP systems.
• Familiarity with updating P&IDs and mechanical/electrical drawings (CAD/SolidWorks).
• Working understanding of PLC logic and automated control systems.
• Prior experience implementing daily management systems or operational excellence frameworks.
• Passion for sustainability, waste reduction, and continuous improvement.

Physical Requirements:

· Ability to navigate all areas of the facility, including office spaces, warehouse areas, and the exterior perimeter.

· Must wear required personal protective equipment (PPE) as necessary to safely perform job duties.

· Ability to stand, sit, and carry out tasks throughout a full shift, with appropriate meal breaks.

· Physically capable of standing, bending, stooping, kneeling, reaching, twisting, lifting, pushing, pulling, climbing, balancing, and crouching as needed.

· Able to lift and move items weighing up to 50 pounds independently and heavier objects with reasonable accommodations.

· Visual acuity sufficient to perform job duties accurately.

· Capable of assessing weights, judging distances, and working at various heights.

Work Schedule:

Typically, Monday-Friday 7am-4pm with flexibility to support a 24/7/365 operation as needs 

arise.

Compensation:

At Cayuga Milk Ingredients, we value a fair and comprehensive approach to compensation. Our wage range for this role is determined by various factors, including skill sets, experience, training, licensure, certifications, and organizational needs. It is not typical for an employee to start at or near the top of the range for the position. Compensation decisions are made based on individual job circumstances considering skill level, previous experience, and education requirements.

Equal Opportunity Employer:

Cayuga Milk Ingredients is committed to providing equal employment opportunities to all employees and applicants without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws. This policy applies to all aspects of employment, including recruitment, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.

Non-Discrimination Policy:

The contractor will not discriminate against employees or applicants for discussing or disclosing their own pay or the pay of others. However, employees with access to compensation information as part of their job duties are prohibited from disclosing this information to unauthorized individuals, except in specific circumstances outlined by applicable laws and regulations (41 CFR 60-1.35(c)).

General Statement: 

All Cayuga employees recognize that the success and prosperity of the company is everyone’s responsibility. All employees are expected to treat each other in a positive, respectful, and professional manner, to be at work for their assigned shift and to work safely as a team. Employees must be self-starters who can relate to all levels of the organization.

Disclaimer:

o All requirements are subject to possible modification to reasonably accommodate individuals with disabilities.

o This job description in no way states or implies that these are the only duties to be performed by the employee occupying this position. Employees will be required to follow any other job-related instructions and to perform any other job-related duties requested by their supervisor.

o The company reserves the right to add to or revise an employee's job duties at any time at its sole discretion.

o This document does not create an employment contract, implied or otherwise, other than an “at will” employment relationship.