KPS Global (KPSG) is the North American industry leader in the manufacture, production, and installation of walk-in coolers and freezers.  KPSG’s end-product serves many channels within the retail food market as well as industrial applications.  KPSG is based in Fort Worth, Texas with engineering activities centralized in the Fort Worth facility (along with Finance, Human Resources, Customer Operations, Sales, and Installation Services), supporting product manufacturing in four other  locations: San Dimas, CA; Piney Flats, TN; Conyers, GA; and Goodyear, AZ.

The Manufacturing Engineer will focus on optimizing and improving our predominantly manual production processes, as well as providing manufacturing solutions for our current line of products and those new proposed through our research and development initiatives. The Manufacturing Engineer requires possessing a strong understanding of manufacturing principles, a hands-on approach, flexibility, and the ability to work collaboratively with production teams to drive efficiency, quality and safety across all manufacturing facilities. This role plays a big part in ensuring KPS Global is at the forefront of offering value added to our customers while internally improving throughput, reducing operating costs, and outstanding service to internal and external customers.

Major Responsibilities 

Process Improvement: 

• Analyze existing manual production processes to identify areas for improvement in efficiency, quality, and cost
• Develop and implement process improvements through work instructions, tooling modifications, and ergonomic enhancements
• Conduct time studies and motion analysis to optimize workflow and reduce cycle times
• Implement Lean Manufacturing principles to eliminate waste and improve flow
• Perform pilot tests, often required behind new product development, supply chain, etc. to identify potential problems, assess feasibility, and refine methodologies before full-scale implementation
• Identify potential failure modes within a manufacturing process through PFMEA

Work Instruction Development & Maintenance:

• Create and maintain clear, concise, and accurate work instructions for all manual production processes
• Train production personnel in new and revised work instructions
• Ensure work instructions are readily available and up to date
• Review engineering changes and take appropriate measures to ensure all product documentation for the affected operations

Tooling & Fixture Design & Implementation:

• Design and implement simple tooling and fixtures to improve ergonomics, accuracy, and efficiency of manual operations
• Collaborate with production personnel to understand tooling needs and ensure effective implementation
• Work with outside vendors to procure tools and fixtures when needed

Production Support:

• Provide technical support to production personnel to resolve manufacturing issues
• Assist with troubleshooting and problem-solving during production
• Assist in the training of new production employees
• Analyze, report and optimize production cost structure
• Increase production speed generating cost savings and free capacity

Quality Control:

• Collaborate and support the implementation of quality control procedures to ensure consistent product quality
• Investigate and resolve quality issues related to manual processes
• Participate in root cause analysis and implement corrective actions

Safety:

• Collaborate and support safety assessments of manual processes and identify potential hazards
• Implement safety improvements to reduce the risk of injury
• Ensure compliance with all safety regulations

Documentation:

• Maintain accurate records of process changes, tooling designs, and quality control data
• Generate reports on process performance and improvement initiatives
• Collaborate and support maintenance of Bills of Materials with Product Engineering
• Support the development of global manufacturing engineering standards

Required Skills, Experience, Education & Certifications

• BS degree: MS preferred (Manufacturing / Industrial Engineering desired)
• 5+ years of experience in manufacturing, process design, or related area
• In depth working knowledge of continuous improvement processes – Toyota Production Principles and Six Sigma methodology (Green Belt / Black Belt Certification desirable)
• Proficiency in Minitab and Excel Statistical ToolPak
• Proven ability to improve production speed and flow
• Ability to work cross-functionally throughout all levels of an organization to manage change and process implementations
• A demonstrated track record of developing and training employees – high level of employee engagement, “comfortable” in both the factory and office environment
• Completion of at least one large scale project where significant cost savings were achieved

Desired Attributes

• Curious nature, investigates thoroughly
• High energy, easy to work with style, functions with different leadership styles and projects seamlessly
• Excellent proven “people” skills, works well with all levels, tailors’ one’s delivery (verbal and written) in light of the audience, advocate of employee engagement
• Apply theory and tools in a practical and appropriate fashion relative to desired outcome  
• Large appetite to understand the business in entirety – the customer base and channels, the product and function, manufacturing processes (strengths and areas needing improvement), and product installation challenges
• The focus may be site specific, however the expectation is to collaborate with peers across all manufacturing facilities to standardize procedures and processes, including sharing best practices, issue resolution, etc

KPS Global values its outstanding people who are deeply committed to providing innovative, high-quality service to clients from coast to coast. As a member of the KPS team, you’ll be part of an exciting and modern company culture where you will enjoy professional flexibility and benefit from an environment where creativity, innovation, and hard work are rewarded.