Operational Excellence Engineer

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This is a hybrid position that requires onsite presence for one week per month at one of the following plant locations: San Carlos, CA; Lynchburg, VA; or Saint-Jean-sur-Richelieu, QC.

Summary

Delta Star Inc. is seeking a strategic, results-driven Operational Excellence Engineer to lead performance improvement and transformation across manufacturing processes and value streams. This role is a key driver of operational success-combining deep technical expertise, lean principles, and cross-functional leadership to improve safety, quality, delivery, cost, and productivity. If you thrive in complex environments and enjoy driving measurable business impact, we want to hear from you!

What You’ll Do

As an Operational Excellence Engineer, you will serve as a subject matter expert and process owner, leading continuous improvement and transformation initiatives across the organization. You’ll partner with Operations, Engineering, Quality, and other teams to standardize best practices, eliminate waste, and implement scalable improvements. You’ll also help shape the future of manufacturing by evaluating new technologies and advancing operational capabilities.

A Day in the Life

Your day may include facilitating a Kaizen event, analyzing value stream performance, or collaborating with plant leadership to improve workflow and reduce inefficiencies. You’ll lead cross-functional projects, track key performance metrics, and develop improvement roadmaps that align with broader business objectives. Whether you’re standardizing processes across sites or mentoring teams on Lean tools, your work directly drives measurable improvements in operational performance.

Specific Duties

• Own and manage performance of assigned manufacturing processes and value streams.
• Develop and maintain value stream maps to identify waste and improvement opportunities.
• Lead Kaizen events, continuous improvement initiatives, and problem-solving activities.
• Deploy Lean tools such as 5S, standard work, and visual management systems.
• Define, update, and standardize SOPs, work instructions, and process documentation.
• Develop and execute improvement roadmaps aligned with business priorities.
• Track and communicate operational KPIs and financial impact of improvements.
• Collaborate with Engineering and Quality to ensure manufacturability and compliance.
• Support facility layout optimization and workflow improvements.
• Drive standardization of best practices across multiple sites.
• Evaluate emerging technologies and manufacturing innovations.
• Conduct site visits to assess performance and support implementation efforts.
• Participate in benchmarking, supplier visits, and industry events to identify best practices.

What We’re Looking For

We’re looking for a high-impact change leader with strong operational expertise and the ability to drive transformation through structured problem-solving and cross-functional influence.

Position Requirements

• Bachelor’s degree in Industrial, Mechanical, Electrical, or Manufacturing Engineering.
• 5-10 years of experience in manufacturing, engineering, or operational excellence roles.
• Proven experience leading cross-functional projects and influencing stakeholders without direct authority.
• Experience with Lean, Six Sigma, Value Stream Mapping, Kaizen, or related methodologies.
• Experience driving organizational change and process standardization.
• Experience in transformer or heavy manufacturing environments preferred.
• Multisite experience preferred.
• Fluency in English required; French or Spanish a plus.

Skills & Competencies

• Advanced knowledge of Lean Manufacturing, Six Sigma, 5S, and continuous improvement tools.
• Strong understanding of manufacturing processes, workflow optimization, and performance metrics.
• Ability to analyze SQDC metrics and develop data-driven solutions.
• Strong financial acumen with ability to quantify business impact.
• Exceptional change management, coaching, and stakeholder engagement skills.
• Ability to lead and influence cross-functional teams without direct authority.
• Strong project management and execution capability.
• Experience developing standard work and training materials.
• Working knowledge of CAD, manufacturing drawings, and process design.
• Proficiency with Microsoft Office, Project, and ERP systems (e.g., Dynamics 365).
• Ability to balance strategic thinking with hands-on execution.

Key Performance Indicators (KPIs)

• Improvement in Safety, Quality, Delivery, and Cost (SQDC) metrics
• Completion and impact of continuous improvement initiatives
• Standardization and adoption of best practices across sites
• Measurable financial impact (cost savings, productivity gains)
• Reduction in process inefficiencies and waste
• Stakeholder engagement and change adoption success

Travel Requirements

• Approximately 25-50% travel, including domestic and international
• Regular travel across U.S. and Canadian facilities
• Remote-capable with one week per month onsite at a Delta Star facility

Why Join Us?

At Delta Star, you'll be part of a supportive and forward-thinking team that values professionalism, efficiency, and exceptional service. We offer a comprehensive benefits package to support you and your family, including medical, dental, vision, life, and disability coverage. Our retirement offerings vary by location but include employer contributions to retirement plans, an Employee Stock Ownership Plan (ESOP), and a corporate bonus plan.

You'll also enjoy paid time off, sick pay, floating holidays, and access to programs such as flexible spending accounts or similar consumer benefits. Additionally, we provide education assistance to help you grow in your career.

At Delta Star, we're committed to helping you thrive both personally and professionally.

Please note that the salary range displayed applies only to positions located in California and Virginia. Compensation for positions based in Canada is determined according to local market conditions and may differ from the salary range shown.

The salary range for this position is $107,500 - $134,400 in the State of Virginia

The salary range for this position is $139,300 - $174,200 in the State of California
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CA

107500 - 134400

NO Security Clearance