Industrial Engineer

Role Purpose
Design, improve and sustain safe, reliable manufacturing systems that integrate people, equipment, materials and information. The Industrial Engineer translates ASD operating priorities into practical improvements in Safety, Quality, Delivery, Cost, Cash and People (SQDCCP), with emphasis on work measurement, labor standards, capacity, productivity and material flow.  Work directly with operators, supervisors and value stream managers to solve operating problems at the gemba, establish repeatable processes and develop plant capability through the ASD Lean Operating System / D.O.O.R. Performance System. Deliver measurable improvements and verify that benefits are sustained in daily operations.

Core Accountabilities Safety, Ergonomics and Work Design

• Apply the ASD Safety Golden Rules and partner with EHS to identify and reduce ergonomic, handling and process risks. Integrate safe work methods into workstation design and standard work.
• Evaluate reach, posture, lifting, repetitive motion and material presentation; recommend practical engineering controls and verify effectiveness with affected employees.
• Ensure proposed changes receive required safety, quality and technical reviews before implementation. Escalate unsafe conditions promptly.

Work Measurement and Labor Standards

• Conduct time studies, work sampling and method analysis across shifts and representative product mixes. Separate manual time, machine time, setup, walking, waiting and avoidable losses.
• Develop and maintain documented labor and setup standards using approved methods, representative observations and justified allowances. Validate methods with operators and supervisors and update standards after process changes.
• Create standard work, work instructions and labor-balance charts with Operations and Quality. Establish sustainable staffing models that reflect demand, mix, training, breaks and operating constraints.

Core Accountabilities — Continued Capacity, Constraints and Production Flow

• Develop demonstrated-capacity models using product mix, cycle times, changeovers, yield, downtime and available operating hours. Distinguish theoretical capacity from sustainable output.
• Identify system constraints and improve throughput through line balancing, setup reduction, workload redistribution and targeted loss elimination. Avoid improving local utilization at the expense of total flow.
• Support Materials and Planning with capacity, routing and run-rate inputs for demand planning, scheduling, build-ahead decisions and backlog recovery. Quantify gaps and alternatives before customer commitments are made.

Layout and Materials Flow

• Design plant, cell and workstation layouts that improve safety, flow, space utilization and access for maintenance. Evaluate point-of-use storage, replenishment routes and packaging with Materials and Operations.
• Map current and future material and information flows; reduce unnecessary travel, handling, queue time and work-in-process. Establish pull, replenishment and inventory parameters with Materials where appropriate.
• Apply these methods to OHD door and component manufacturing, assembly, finishing, packaging and shipping processes as applicable to the assigned facility.

ASD Lean Operating System and Problem Solving

• Support SQDCCP daily management, tiered escalation, leader standard work, visual controls and plant bowler priorities. Translate gaps into scoped projects with baselines, owners, milestones and sustainment plans.
• Facilitate PDCA, root-cause analysis, kaizen, 5S, standard work, value stream mapping and changeover reduction. Select tools based on the problem and coach employees in their practical use.
• Partner with Quality and Manufacturing Engineering on defect reduction, process capability, error prevention and equipment-loss analysis. Use OEE where relevant and distinguish availability, performance and quality losses.

Financial Benefits and Project Execution

• Build business cases with Finance, including baseline, investment, implementation cost, annual benefit, in-year timing and payback. Separate realized savings, cost avoidance, capacity release and working-capital release; prevent double counting.
• Lead assigned projects through implementation, training and operational handoff. Verify benefits with Finance and operating owners and confirm sustained performance after completion.
• Transfer methods and documentation from consultants or contractors to OHD employees. Share proven improvements across ASD plants using common standards.

Manufacturing Data, Launches and Capability

• Maintain engineering inputs to ERP routings, labor standards, setup times and capacity data through approved change controls. Partner with Materials, Finance and IT to resolve data inconsistencies.
• Use Excel, Power BI and approved manufacturing systems to analyze losses and trends. Validate source data and definitions before using results to recommend staffing or investment decisions.
• Support new-product introductions, equipment installations, automation and production transfers with layout, staffing, throughput and readiness analysis. Coordinate technical design and commissioning with Manufacturing and Product Engineering.
• Train operators and supervisors on revised methods; verify adoption across shifts. Develop technical and business capability through cross-functional assignments, supporting future opportunities in supervision, manufacturing engineering, planning and other business roles based on performance and readiness.

Decision Rights and Escalation

• Stop work and escalate an immediate safety risk in accordance with site policy; promptly raise product-integrity concerns to Operations and Quality.
• Own technical analysis, study documentation and assigned improvement deliverables. Implement changes only within approved scope, budget and delegated authority.
• Recommend staffing, labor standards, layouts, scheduling parameters and capital changes. Plant leadership and the relevant functional owners retain approvals for workforce, production commitments, quality release and expenditure.
• Escalate capacity shortfalls, unreliable standards, benefit gaps and project risks early, with quantified impact and recommended countermeasures.

Performance Measures

Targets are set through the ASD operating plan, plant bowler and approved project portfolio. Assess the engineer on assigned deliverables and verified contribution to SQDCCP; plant leaders retain accountability for overall site results.

Required Qualifications

• Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering or a related engineering discipline.
• Demonstrated manufacturing experience through employment, internship or cooperative education, with practical exposure to work measurement, production analysis or process improvement. Project scope and independence will match the assigned job level.
• Working knowledge of time studies, labor standards, line balancing, capacity analysis, layout design, ergonomics and Lean problem solving.
• Ability to analyze operational data, validate assumptions and communicate recommendations clearly to operators, managers and functional partners.
• Proficiency with Excel and the ability to read process layouts and engineering drawings; familiarity with ERP or manufacturing data systems.
• Ability to lead projects without direct supervisory authority and work effectively across shifts and functions.

Preferred Experience

• Two or more years of industrial or manufacturing engineering experience in a high-mix production environment.
• Experience in building products, metal fabrication, forming, finishing, assembly, packaging or comparable processes.
• Hands-on improvement results using Lean or Six Sigma methods; relevant certification is helpful but does not replace demonstrated application.
• Experience with CAD layout tools, Power BI, statistical analysis, discrete-event simulation or automation business cases.
• Experience validating financial benefits, updating ERP standards or supporting launches and production transfers.

Work Requirements

• Primarily an on-site role with regular presence in active manufacturing and warehouse areas and participation across shifts as needed.
• Travel to other ASD facilities, suppliers or training locations as business needs require.
• Follow all site safety requirements and use required personal protective equipment. Perform essential duties, including observing processes and accessing production areas, with or without reasonable accommodation.