Process Improvement Engineer

Role Overview

Process Improvement Engineer at Al Shirawi Group, a leading manufacturing operation in the GCC region specializing in HVAC ducts, sheet metal, and acoustic products.

Company Overview

Founded in 1971, Al Shirawi Group is a conglomerate serving the Middle East across trading, industrial, distribution, contracting, and service industries. The Group operates across the GCC region with offices in Qatar, Oman, Kuwait, India, and Egypt, supported by a 10,000+ workforce and over 35 companies. Leminar, the manufacturing division, is an ISO 9001:2008 certified producer of HVAC ducts, sheet metal, and acoustic products established to serve the growing HVAC industry with premium products and timely deliveries.

Role Purpose

Drive continuous improvement and operational excellence across manufacturing facilities using Lean and Six Sigma methodologies. Lead cross-functional improvement initiatives to reduce waste and variation, enhance efficiency and quality, and improve cost performance through data-driven problem-solving and shop-floor engagement.

Key Responsibilities

Improvement Projects & Methodology

• Lead and facilitate Kaizen events, value stream mapping exercises, and Lean/Six Sigma improvement projects across production lines.
• Identify sources of waste, variation, and inefficiency using DMAIC (Define, Measure, Analyse, Improve, Control) methodology.
• Manage improvement project pipelines, ensuring projects are prioritized, resourced, and completed on schedule.
• Support new product introduction and process design with a continuous improvement mindset.

Data Analysis & Statistical Tools

• Collect, analyse, and interpret process and quality data using statistical tools (SPC, capability analysis, hypothesis testing, DOE).
• Drive root cause analysis for quality defects, scrap, downtime, and non-conformances.

Process Implementation & Control

• Develop and implement standard work, visual management systems, and process control plans.
• Partner with production supervisors and operators to implement 5S, TPM, SMED, and other Lean tools on the shop floor.
• Establish and maintain production line methods and implementation processes.

Quality & Standards Alignment

• Collaborate with quality assurance to align improvement initiatives with ISO/IATF and other applicable quality management standards.
• Conduct quality control checks to ensure manufacturing of products in accordance with cost, quality, and quantity specifications.

Performance Management & Reporting

• Track and report key performance indicators (OEE, first-pass yield, cycle time, defect rates, cost savings).
• Prepare and present project results, cost-benefit analyses, and improvement recommendations to plant leadership.

Training & Development

• Train and coach employees at all levels on Lean Six Sigma principles and tools.

Operations & Personnel

• Oversee plant operations and personnel activities for production output.
• Ensure production meets customer specifications and on-time delivery of products.
• Manage material and manpower planning to support production requirements.
• Ensure adequate manpower availability to prevent hindrance to production.
• Manage human resources at floor level.
• Supervise work activities to ensure personnel are working properly and safely.
• Plan, direct, regulate, and coordinate shop-floor functions.
• Maintain inventory stock levels.
• Oversee equipment maintenance.
• Maintain tag lists and production documents.
• Feed data into computer systems for plasma cutting with QC checks.
• Communicate with customers regarding deviations or clarifications.

Qualifications & Experience

• B.Tech in Industrial or similar degree.
• Lean & Six Sigma certification from IASSC, ASQ, or equivalent (Green Belt minimum; Black Belt preferred).
• 3–5+ years of hands-on manufacturing experience.
• Experience in manufacturing or fabrication industries.
• Familiarity with ERP/MES systems.
• Working knowledge of ISO 9001 and IATF 16949 quality management systems.
• Experience with automation, robotics, or Industry 4.0 initiatives.

Skills & Competencies

• Analytical and data-driven decision-making.
• Strong ownership and accountability for project outcomes.
• Ability to lead change management on the shop floor.
• Attention to detail balanced with big-picture process thinking.
• Collaborative, coaching-oriented leadership style.
• Strong facilitation and training capabilities.
• Good knowledge of business process improvement and implementing different software systems.