The Expert Factory Engineer is responsible for leading the design, optimization, and continuous improvement of complex manufacturing systems that integrate people, technology, materials, information, and processes.
The role provides advanced expertise in process engineering, Lean methodologies, operational excellence, and data-driven improvement to increase productivity, quality, flexibility, and cost efficiency across the plant. The Expert Factory Engineer also drives the standardization and replication of best practices within the PowerCo plant network.
Key Responsibilities
1. Process Optimization & Operational Excellence
- Lead Lean, Six Sigma, Kaizen, and continuous improvement initiatives to eliminate waste, improve process stability, and increase operational performance.
- Drive the application and continuous improvement of PowerCo Excellence System tools, including 5S, Problem Solving, Quick Setup, Shopfloor Management, and related methodologies.
- Conduct process mapping, value stream analysis, bottleneck analysis, and workflow redesign to optimize end-to-end processes.
- Identify and implement opportunities to improve productivity, quality, lead time, flexibility, and overall equipment and resource utilization.
2. Production & Industrial Engineering
- Design and optimize production systems, plant layouts, workflows, and capacity models to ensure the effective use of space, equipment, and workforce.
- Perform time studies, motion studies, and process analysis to establish standards and identify productivity improvements.
- Develop and maintain standard work, standard worksheets, SOPs, and other process documentation.
- Support the industrialization and ramp-up of new processes and ensure their integration into stable and efficient production systems.
3. Systems Design & Strategic Planning
- Design and optimize integrated manufacturing systems across production, maintenance, quality, logistics, and supply chain interfaces.
- Translate operational and business requirements into sustainable engineering solutions aligned with long-term plant objectives.
- Assess future capacity, process requirements, and operational scenarios to support strategic production planning.
- Identify opportunities for standardization and replication of successful solutions across the PowerCo plant network.
4. Data Analytics & Performance Management
- Collect, analyze, and interpret operational data to identify trends, deviations, root causes, and improvement opportunities.
- Define, monitor, and report relevant KPIs to support data-driven decision-making and performance management.
- Develop and utilize digital Value Stream Mapping (VSM) and other analytical tools to visualize processes, identify bottlenecks, and evaluate improvement scenarios.
- Establish performance baselines and quantify the impact and sustainability of improvement initiatives.
5. Cost & Resource Optimization
- Identify and implement cost-reduction opportunities while maintaining safety, quality, compliance, and operational requirements.
- Optimize workforce allocation, equipment utilization, material flow, and other operational resources.
- Evaluate the business impact of engineering solutions and provide data-driven recommendations to management.
6. Collaboration, Knowledge Sharing & Stakeholder Management
- Work closely with Production, Maintenance, Quality, Logistics, Supply Chain, and other relevant functions to develop and implement sustainable solutions.
- Act as a technical expert and advisor for operational excellence and industrial engineering topics.
- Coach and support teams in the application of Lean, problem-solving, standardization, and continuous improvement methodologies.
- Coordinate closely with PowerCo Headquarters in Salzgitter and other plants within the PowerCo network, including St. Thomas, to exchange knowledge, benchmark performance, and implement best practices.
