Lean Process Engineer

Hendrick Technical SolutionsLocation: 4400 Papa Joe Hendrick Blvd, Charlotte, North Carolina 28262

Hendrick Technical Solutions is a dynamic and growing force within the defense industry. This role operates within a fast-paced, mission-critical environment, focusing on challenging and impactful projects that directly enhance national security.  This unique environment combines the agility and innovation typical of a startup with the stability, proven culture, and established resources of Hendrick Technical Solutions.   

Summary: The Lean Process Engineer is responsible for designing, improving, and sustaining manufacturing processes that drive safety, quality, delivery, and operational excellence throughout Hendrick Technical Solutions. This role partners closely with Manufacturing, Quality, Engineering, and Production to develop standardized work, optimize production flow, eliminate waste, improve productivity, and ensure repeatable manufacturing processes for defense and commercial products.

The Lean Process Engineer serves as the process owner for manufacturing workflows and leads continuous improvement initiatives from concept through implementation. This position combines lean manufacturing principles, industrial engineering techniques, and hands-on production support to improve efficiency while maintaining the highest standards of quality and regulatory compliance.

Essential Duties and Responsibilities include the following:

Process Development

• Develop, document, and continuously improve manufacturing processes for fabrication, machining, welding, assembly, powder coating, inspection, and packaging operations.

• Design manufacturing workflows that improve safety, quality, productivity, and throughput.

• Establish standardized work instructions, visual work aids, and process documentation.

• Support New Product Introduction (NPI) by developing manufacturing methods and production processes.

• Participate in Design for Manufacturability (DFM) reviews with Engineering.

Lean Manufacturing & Continuous Improvement

• Lead Lean Manufacturing initiatives utilizing methodologies including:

• 5S

• Kaizen

• Value Stream Mapping

• Standard Work

• Visual Management

• Waste Elimination

• Error Proofing (Poka-Yoke)

• Root Cause Analysis

• Identify and eliminate non-value-added activities.

• Improve process flow and reduce cycle time through continuous improvement initiatives.

• Facilitate cross-functional Kaizen events and process improvement workshops.

• Measure and report operational performance using established KPIs.

Process Validation

• Validate new and revised manufacturing processes in lockstep with production breakpoints.

• Conduct process capability studies where applicable.

• Develop and implement process controls to ensure repeatable manufacturing performance.

• Support production readiness reviews for new equipment and manufacturing cells.

Quality Improvement

• Partner with Quality Engineering to reduce internal defects and customer escapes.

• Analyze production data to identify recurring quality issues.

• Support corrective and preventive action activities through the NCR process.

• Develop process improvements that reduce variation and improve product consistency.

Documentation & Standardization

• Develop and maintain:

• Manufacturing work instructions

• Standard work

• Process flow diagrams

• Visual controls

• Manufacturing routes

• Manufacturing process maps

• Ensure documentation accurately reflects current production methods.

• Support document revisions resulting from engineering changes and process improvements.

Required Qualifications

• Bachelor’s degree in industrial engineering, Manufacturing Engineering, preferred.

• Minimum 5 years of industrial engineering, manufacturing engineering, process engineering, or continuous improvement experience.

• Experience in defense, aerospace, motorsports, or other high-mix/low-volume manufacturing environments.

• Experience in fabrication, machining, welding, assembly, or industrial manufacturing environments.

• Demonstrated success implementing Lean Manufacturing principles.

Preferred Qualifications

• Experience supporting automated manufacturing or robotic welding cells.

• Experience with ERP/MRP systems.

• Green Belt or Black Belt certification in Lean Six Sigma.

• Familiarity with ISO 9001, AS9100, or other regulated quality management systems.

Knowledge, Skills & Abilities

• Strong understanding of Lean Manufacturing and Industrial Engineering principles.

• Ability to read and interpret engineering drawings and GD&T.

• Experience developing standardized work and manufacturing documentation.

• Excellent analytical and problem-solving skills, using data to drive decision making.

• Strong project management and organizational abilities.

• Ability to adapt to changing priorities.

• Excellent communication and facilitation skills, coaching and mentoring people at all levels of the organization.

• Coach supervisors and operators on Lean Manufacturing principles.

• Ability to influence change across cross-functional teams.

• Support development of a continuous improvement culture throughout the organization.

• Proficiency with Microsoft Office applications; experience with Visio, Power BI, or similar data visualization tools preferred.

Education/Experience:

• Bachelor’s degree in industrial engineering, Manufacturing Engineering, preferred.
• Minimum 5 years of industrial engineering, manufacturing engineering, process engineering, or continuous improvement experience.
• Experience in defense, aerospace, motorsports, or other high-mix/low-volume manufacturing environments.
• Experience in fabrication, machining, welding, assembly, or industrial manufacturing environments.
• Demonstrated success implementing Lean Manufacturing principles.

This role subject to International Traffic in Arms Regulations (ITAR) requirements and as such, U.S. Citizen, Permanent Resident or U.S. Person Status Required. 

Hendrick is an Equal Opportunity employer. Minorities, women, veterans, and individuals with disabilities are encouraged to apply. For more information regarding the EEOC, please visit https://www.eeoc.gov/sites/default/files/2023-06/22-088_EEOC_KnowYourRights6.12ScreenRdr.pdf.