Continues Improvement Engineer at Bayer

Job Purpose:

• The Continuous Improvement Technician is responsible for identifying, analysing, implementing, and sustaining improvements across the production environment. The role supports improved safety, quality, delivery, cost, productivity, and equipment reliability through OEE tracking, time and motion studies, waste elimination, data analysis, and structured monitoring of all continuous improvement projects.

Key Responsibilities:

Continuous Improvement and Lean Manufacturing

• Drive improvement initiatives using Lean Manufacturing, Kaizen, 5S, TPM, visual management, and structured problem-solving methodologies.
• Identify production bottlenecks, process variation, waste, and non-value-added activities.
• Facilitate or support Kaizen events, improvement workshops, and shop-floor problem-solving sessions.
• Conduct root cause analysis for recurring operational losses and support corrective and preventive actions.
• Support the development, revision, and sustainability of standard operating procedures and standard work.
• Verify that completed improvements are embedded, audited, and sustained.

OEE Monitoring and Improvement

• Monitor and report Overall Equipment Effectiveness across production lines and equipment.
• Analyse availability, performance, and quality losses, including breakdowns, changeovers, minor stops, speed losses, defects, and rework.
• Maintain daily, weekly, and monthly OEE dashboards and loss summaries.
• Develop and track action plans to improve equipment utilisation, line performance, output, and reliability.
• Work with Production, Engineering, Maintenance, and Quality teams to eliminate recurring losses.
• Validate performance improvements and quantify operational benefits.

Time and Motion Studies

• Conduct time and motion studies for operators, equipment, changeovers, material movement, and production tasks.
• Measure cycle times, waiting time, travel, delays, and work content using consistent observation methods.
• Develop and maintain standard times and documented work measurement records.
• Identify opportunities for improved workflow, workstation layout, labour utilisation, ergonomics, and method standardisation.
• Support line balancing, capacity analysis, manpower planning, and productivity improvement.
• Communicate findings objectively and support implementation of approved improvements.

Continuous Improvement Project Monitoring

• Maintain a central register of all continuous improvement projects, including owners, objectives, milestones, status, risks, projected savings, and realised benefits.
• Track projects against agreed scope, timelines, actions, and performance targets.
• Coordinate routine project reviews and follow up overdue actions with responsible persons.
• Apply clear project governance and escalation where progress, resources, or benefits are at risk.
• Prepare concise project status reports for management review.
• Verify project closure, benefits realisation, handover, and sustainability controls.

Data Analysis and Reporting

• Collect, clean, validate, analyse, and interpret production and operational data.
• Monitor OEE, downtime, throughput, yield, scrap, rework, cycle time, labour efficiency, and cost savings.
• Build and maintain production dashboards, KPI scorecards, Pareto analyses, and trend reports.
• Use data to identify improvement priorities, quantify losses, and support evidence-based decisions.
• Present findings and recommendations clearly to production teams and management.
• Support automation of recurring reports and project tracking where practical.

Training, Engagement, Safety and Quality

• Promote a practical continuous improvement culture on the shop floor.
• Coach operators and supervisors in basic Lean tools, standard work, 5S, OEE loss identification, and problem solving.
• Encourage employee participation in improvement ideas and recognition programmes.
• Ensure proposed changes comply with safety, quality, environmental, and operational requirements.
• Participate in risk assessments and change-control activities before implementing process changes.

Minimum Qualifications and Experience:

• National Diploma or Degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, Operations Management, Production Management, or a related field.
• Typically 2 to 5 years of experience in a manufacturing, production, FMCG, packaging, or process environment.
• Practical experience with OEE analysis, time and motion studies, production data, and improvement projects.
• Experience working cross-functionally with Production, Maintenance, Engineering, and Quality teams.