COS Project Engineer

The Carlisle Operating System (COS) is the continuous improvement system at Carlisle Construction Materials. The COS Project Engineer applies engineering principles, manufacturing systems analysis, statistical methods, and Lean Six Sigma methodologies to evaluate and improve manufacturing and business processes. Working with engineering, quality, maintenance, operations, plant leadership, and local COS resources, this position analyzes process capability and equipment performance, identifies sources of variation and waste, develops and validates technical solutions, and implements sustainable improvements that enhance Safety, Quality, Delivery, Cost, and productivity. The role requires independent engineering judgment, strong analytical and technical problem-solving skills, and the ability to document and communicate complex engineering findings to plant personnel and management.

Employees in this position will typically work 8 hours a day, Monday through Friday, although hours may be adjusted based on customer and business requirements. Travel is expected to be around 20%-40%, depending on business needs.

• Apply industrial and manufacturing engineering principles within the COS Framework to improve process flow, production system performance, and operational capability across CCM.
• Translate strategic and functional goals into technically defined engineering improvement projects, including problem statements, baseline data, design requirements, project scope, validation criteria, and performance measures.
• Develop engineering project charters and technical analyses; quantify and report validated improvements in process capability, throughput, equipment effectiveness, quality, cost, and other COS metrics.
• Analyze manufacturing processes, material flow, equipment interfaces, work methods, and production data to identify engineering opportunities that improve safety, quality, capacity, throughput, and cost.
• Perform technical root cause analysis using engineering problem-solving methods such as DMAIC, A3, 8D, fault-tree analysis, and cause-and-effect analysis to reduce process variation and recurring manufacturing failures.
• Use Minitab and other analytical tools to perform statistical process control, measurement system analysis, process capability studies, regression analysis, hypothesis testing, and Design of Experiments to identify critical process variables and verify engineering solutions.
• Develop, evaluate, and validate process designs, equipment modifications, fixtures, mistake-proofing devices, and manufacturing methods to improve safety, repeatability, quality, and productivity.
• Support PFMEA, control plan, risk assessment, CAPA, process validation, and engineering change activities to ensure that process risks and technical requirements are properly identified and controlled.
• Lead cross-functional engineering projects from technical assessment through design, implementation, validation, control, and read-across deployment, partnering with manufacturing, process engineering, quality, maintenance, EHS, supply chain, and operations.
• Develop and update technical standards, process specifications, process flow diagrams, standard work, visual work instructions, control plans, and other engineering documentation; provide technical training on the approved standards.
• Evaluate control plans, process controls, and sustainment systems; identify technical gaps and implement corrective actions that maintain process capability and performance gains.
• Partner with plant and functional leadership to prioritize engineering improvement needs and communicate validated technical solutions and engineering best practices across the organization.
• Lead and participate in shop-floor Kaizen events as an engineering subject-matter resource, using process observations, time studies, data analysis, risk assessment, and technical experimentation to design and validate improved methods.
• Engineer and implement improvements using MDI, 5S, TPM, value stream mapping, process mapping, SQDC, standard work, OEE, line balancing, mistake-proofing, and the COS Framework, with emphasis on measurable manufacturing-system performance.
• Other duties as assigned

• Demonstrated knowledge of industrial and manufacturing engineering methods, including process analysis, facility and material flow, line balancing, standard work, time studies, value stream mapping, mistake-proofing, TPM, OEE, MDI, and root cause analysis.
• Strong understanding of manufacturing processes, equipment and process interactions, production systems, quality requirements, and the relationship between engineering decisions and customer requirements.
• Strong written and verbal technical communication, engineering problem-solving, analytical, presentation, facilitation, and cross-functional collaboration skills.
• Ability to manage multiple engineering projects, technical investigations, validation activities, and implementation schedules.
• Working knowledge of engineering and manufacturing software systems, including Microsoft Office, SAP, Minitab, Wonderware, and production data-collection systems.
• Ability to identify, scope, execute, validate, and sustain multiple engineering improvement projects simultaneously.
• Ability to translate complex engineering analyses, statistical findings, and technical recommendations into clear terms for all organizational levels.
• Ability to prepare clear technical reports, engineering specifications, validation summaries, procedures, and implementation documentation.
• Ability to distinguish value-added and non-value-added activities and redesign process flow to reduce waste, constraints, and unnecessary motion or handling.
• Demonstrated ability to apply Six Sigma and statistical engineering tools, including DMAIC, Measurement System Analysis, Statistical Process Control, process capability analysis, regression, hypothesis testing, and Design of Experiments.

• Required:
  • Bachelor’s degree or Licenciatura in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, Systems Engineering, Business Management Engineering, or another engineering discipline directly related to the assigned work.
  • Two or more years of professional engineering experience in manufacturing, process engineering, industrial engineering, manufacturing systems, equipment reliability, or engineering-based continuous improvement.
• Preferred:
  • Experience applying DOE, SPC, PFMEA, control plans, process validation, process capability analysis, and engineering root cause analysis in a manufacturing environment.
  • Master’s degree in Engineering, Engineering Management, or a related technical discipline.
  • Lean Six Sigma Green Belt or Black Belt certification.

• Individual will operate primarily in an office setting or manufacturing setting (depending on location)
  • Work in manufacturing plants will occur, where there could be exposure to dirt, dust, and hotter/colder temperatures than office settings.  
• Ability to high-speed internet connection to facilitate video calls, systems management, and other project related activities.  

OCCASIONALLY

FREQUENTLY

CONTINUOUSLY

(0-30%)

(31-60%)

(61-100%)

LIFTING OR CARRYING

·       1-10 LBS

X

·       11-20 LBS

X

·       21-40 LBS

X

·       41-50 LBS

·       51 OR MORE LBS

PUSHING OR PULLING:

·       1-40 LBS

X

·       41-50 LBS

X

·       51 OR MORE LBS

BENDING OR STOOPING

X

REACHING ABOVE SHOULDER LEVEL

X

DRIVING AUTOMATIC EQUIP. VEHICLES

OPERATE MACHINERY OR POWER TOOLS

CLIMBING (LADDERS, STAIRS, ETC.)

WALKING

X

STANDING

X

SITTING

X

WORKING IN EXTREME TEMPERATURES

REPETATIVE MOTION INCLUDING BUT NOT LIMITED TO: WRISTS, HANDS AND/OR FINGERS)

X

VISION

X

HEARING

X

DEXTERITY

X

HAND EYE COORDINATION

X

Personal Protective Equipment (PPE) Used:

• Eye and hearing protection is required at all times on the production
• Safety toe shoes (steel/composite) on the production
• Other PPE as defined by management within assigned