Continuous Improvement Leader

Description Pennsylvania Transformer Technology, LLC. POSITION DESCRIPTION POSITION TITLE : Continuous Improvement Leader, Dead Tank Breaker Manufacturing EFFECTIVE DATE: 8/10/2026 REV. DATE & NO.:

REPORTS TO: Deputy General Manager
LOCATION
: Canonsburg
DEPARTMENT:
Manufacturing Operations
STATUS
: Full-time
______________________________________________________________________________
Position Description Summary
Pennsylvania Transformer is seeking a results-driven Continuous Improvement (CI) Leader to drive operational excellence across our Dead Tank Breaker manufacturing operations. This role will lead enterprise-wide Lean Six Sigma (LSS) initiatives across manufacturing, engineering, supply chain, quality, and business operations to maximize production efficiency, reduce waste, and support scalable growth. The ideal candidate is a hands-on leader who can coach teams at all levels, drive measurable results, and build a self-sustaining culture of continuous improvement.
Primary Responsibilities:
Strategic Leadership
Develop and execute the site-wide Continuous Improvement strategy aligned with production, quality, and business goals for dead tank breaker manufacturing.
Partner with plant management, engineering, and business unit leaders to identify high-impact improvement opportunities.
Establish CI governance structure, project pipelines, and prioritization frameworks.
Report improvement metrics, savings, and progress to executive leadership.
Manufacturing Operations Improvement
Lead value stream mapping across dead tank breaker production lines (fabrication, tank assembly, bushings, interrupters, control cabinets, final assembly, testing).
Identify and eliminate bottlenecks in welding, machining, painting, assembly, and high-voltage testing operations.
Reduce cycle time, work-in-process (WIP), and non-value-added activities across the production floor.
Drive standard work development and visual management systems on the shop floor.
Partner with production supervisors to implement daily management systems (tiered huddles, gemba walks, andon systems).
Quality & Process Control
Lead root cause analysis and corrective action efforts for defects, rework, and test failures.
Apply Design of Experiments (DOE) and Statistical Process Control (SPC) to critical manufacturing processes (welding parameters, tank sealing, dielectric testing).
Reduce scrap, rework, and warranty-related costs through process capability improvements.
Support first-pass yield improvement initiatives in testing and final inspection.
Supply Chain & Business Operations
Improve material flow, kitting, and point-of-use delivery to reduce line-side inventory and stockouts.
Lead improvement projects in order-to-cash, engineering-to-production handoffs, and procurement lead times.
Support S&OP (Sales & Operations Planning) process improvements to align capacity with demand.
Identify automation and digital transformation opportunities (MES, IIoT, digital work instructions).
Culture & Capability Building
Train and mentor employees at all levels in Lean and Six Sigma methodologies (Yellow Belt, Green Belt, Black Belt curriculum).
Certify and develop internal Green Belts/Black Belts to build a distributed CI capability.
Facilitate Kaizen events, Rapid Improvement Workshops, and problem-solving A3s.
Champion employee-driven suggestion systems and recognition programs.
Foster a culture of daily continuous improvement, safety, and accountability.
Project & Financial Management
Own the CI project pipeline with tracked financial impact (cost savings, cost avoidance, productivity gains).
Manage capital project justifications tied to efficiency improvements.
Present business cases and ROI analysis to senior leadership.
Track and report OEE (Overall Equipment Effectiveness), throughput, safety, and quality KPIs.
All other duties as assigned.
Lean Six Sigma Tools & Methodologies
Lean Tools
5S and workplace organization
Value Stream Mapping (current/future state)
Kaizen events / Rapid Improvement Events
Standard Work and Work Instructions
Visual Management / Andon systems
Kanban and Pull Systems
Single-Minute Exchange of Die (SMED) for changeover reduction
Total Productive Maintenance (TPM)
Poka-Yoke (error-proofing)
Gemba walks and daily management systems
Takt time analysis and line balancing
Heijunka (production leveling)
Six Sigma Tools
DMAIC (Define, Measure, Analyze, Improve, Control) methodology
Statistical Process Control (SPC) and control charts
Process capability analysis (Cp, Cpk)
Root Cause Analysis (5 Whys, Fishbone/Ishikawa diagrams)
Failure Mode and Effects Analysis (FMEA)
Design of Experiments (DOE)
Hypothesis testing and regression analysis
A3 problem solving
Pareto analysis
Measurement Systems Analysis (MSA / Gage R&R)
Business Process Tools
OEE (Overall Equipment Effectiveness) tracking
Theory of Constraints (TOC)
Capacity and demand planning models
Cost of Poor Quality (COPQ) analysis
Knowledge & Skills
Hands-on leadership and shop floor presence.
Ability to influence without direct authority across departments.
Strong facilitation, coaching, and training skills.
Data-driven and results-oriented mindset.
Comfortable balancing strategic initiatives with tactical, day-to-day floor issues.
Strong analytical, project management, and change management skills.
Experience with ERP/MES systems and data-driven decision making.
Education And Experience
Required
Bachelor's degree in Engineering, Operations Management, Industrial Engineering, or related field.
Lean Six Sigma Black Belt certification (or equivalent demonstrated experience).
7+ years of progressive experience in manufacturing continuous improvement, preferably in heavy electrical equipment, power apparatus, or industrial manufacturing.
Demonstrated track record leading Kaizen events and delivering measurable cost/efficiency improvements.
Preferred
Experience in transformer, switchgear, or circuit breaker manufacturing.
Familiarity with high-voltage testing processes and dielectric/mechanical test standards (IEEE, ANSI, IEC).
Six Sigma Master Black Belt certification.
Experience leading union and non-union manufacturing environments.
Physical Job Demands
While performing the duties of this job, the employee is regularly required to sit or stand for extended lengths of time and to walk the production floor to conduct training, Gemba walks, and process observations. The employee frequently is required to use hands to finger, handle, or feel; reach with hands and arms; and talk or hear. The employee must occasionally lift or move objects up to 25 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, and the ability to adjust focus.
The employee may be required to wear PPE and work in proximity to production machinery and equipment.
Prolonged periods of working on a computer and looking at a computer screen are required.
Benefits
Competitive salary
Health, dental, and vision insurance
401(k) with company match
Paid time off and holidays
Professional development, training, and certification support (e.g., Lean Six Sigma)
Working Conditions
Monday through Friday, standard business hours, with periodic presence on the production floor across shifts to deliver and observe training. Additional hours, and occasional evening or off-shift presence, may be required to support training and continuous improvement activities across all shifts.
Disclaimer Clause
The above statements are intended to describe the general nature and level of the work being performed by the employee assigned to this position. They are not exhaustive lists of all duties and responsibilities, knowledge, skills, abilities, physical job demands, and working conditions associated with the position.
Monday through Friday. Overnight, weekend, overtime, and/or travel may be required.