Continuous Improvement Engineer
Job Description
Join the Legacy – Build the Future!
Carolina Foods, the maker of Duchess Brand snacks and the creator of one of America’s first Honey Buns, has been delivering quality and innovation for over 80 years. As a leading manufacturer of sweet baked goods, including honey buns, baked pies, fried pies, and gem donuts, we are entering an exciting phase of growth and expansion. We are looking for motivated and experienced leaders to join our journey and help shape the future!
Job Summary
The Continuous Improvement Engineer supports large-scale industrial bakery operations by driving process optimization, cost reduction, and quality improvement across high-volume, automated production lines. This role focuses on improving efficiency, reducing waste, increasing throughput, and ensuring consistent product quality while maintaining strict food safety and regulatory compliance.
Key Responsibilities
- Analyze end-to-end industrial bakery processes including mixing, fermentation/proofing, baking, cooling, slicing, and packaging
- Lead Lean, Six Sigma, and Kaizen initiatives to improve Overall Equipment Effectiveness (OEE), yield, and labor efficiency
- Identify and eliminate process variation impacting product quality, weight control, and consistency
- Reduce downtime through root cause analysis of equipment failures and process disruptions
- Develop, standardize, and maintain Standard Operating Procedures (SOPs) and work instructions
- Partner with Operations, Maintenance, Quality, and Engineering teams to implement improvements
- Use data and statistical tools to monitor KPIs (waste, scrap, throughput, changeover time, energy usage)Support automation, line balancing, and capacity expansion projects
- Ensure compliance with food safety, sanitation, and regulatory requirements (HACCP, GMP, SQF, BRC, FDA/USDA as applicable)Train production teams on continuous improvement tools and standardized processes
Required Qualifications
- Bachelor’s degree in Industrial Engineering, Food Engineering, Mechanical Engineering, or related field (or equivalent experience)
- Experience in industrial food manufacturing, preferably bakery or grain-based products
- Strong knowledge of high-speed production lines and automated equipment
- Proficiency in Lean manufacturing and continuous improvement methodologies
- Ability to analyze production data and drive fact-based decisions
Preferred Qualifications
Lean Six Sigma Green Belt or Black Belt
Experience with OEE systems, MES, or manufacturing analytics tools
Familiarity with thermal processing, dough handling, and packaging systems
Project management experience in manufacturing environments
Key Skills
Process optimization and waste reduction
Statistical analysis and problem-solving
Cross-functional leadership
Equipment and systems understanding
Change management in union or non-union environments
Physical & Work Requirements
Manufacturing environment with exposure to heat, moving machinery, and food ingredients
Ability to work on the production floor for extended periods
Occasional off-shift or weekend support during trials or implementations
Carolina Foods is an Equal Opportunity Employer. All qualified applicants will be considered regardless of race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.