Full Time Visual Observer Jobs in Houston, TX (NOW HIRING)

Position Code: INDENG FLSA Status: Exempt

Pay Grade: G5-TECH Career Level: Experienced Professional

Job Type: Full-Time Travel: As required

Reports To: Director, Manufacturing Systems & Operations Director of Manufacturing Systems and Operations

1.0 POSITION SUMMARY

The Industrial Engineer improves manufacturing performance across Spike Electric Controls by analyzing end-to-end production and business processes, reducing waste and variation, and implementing sustainable operating methods. Reporting to the Director of Manufacturing Systems and Operations, this role works extensively on the production floor and across Production, Engineering, Supply Chain, Quality, Maintenance, and Operations to improve safety, quality, cost, delivery, productivity, capacity, and throughput. The Industrial Engineer leads assigned improvements from observation and data collection through solution design, implementation, training, performance verification, and sustainment.

2.0 KEY RESPONSIBILITIES

Process Analysis & Continuous Improvement

• Analyze manufacturing and supporting business processes to identify opportunities affecting safety, quality, cost, delivery, productivity, capacity, and throughput.
• Conduct time studies, work sampling, cycle-time analysis, workflow observations, and labor-content reviews to establish reliable performance baselines.
• Develop current-state and future-state process maps, value stream maps, spaghetti diagrams, and other practical representations of product and information flow.
• Identify bottlenecks, constraints, non-value-added activity, process variation, excessive handling, queue time, rework, and other forms of waste using Lean principles.
• Apply structured problem-solving and root-cause methods to define issues, test countermeasures, and prevent recurrence.
• Develop practical recommendations that balance productivity, quality, safety, cost, staffing, equipment, and customer requirements.

Project Leadership & Implementation

• Lead assigned improvement projects from charter, scope, baseline, and target definition through implementation, closeout, and sustainment.
• Develop project plans, milestones, resource requirements, risk controls, and measurable success criteria; communicate progress and decisions to stakeholders.
• Coordinate with Production, Engineering, Supply Chain, Quality, Maintenance, Information Technology, and Operations to implement approved improvements.
• Pilot proposed changes, collect operator feedback, resolve implementation issues, and support training and change adoption before full rollout.
• Measure post-implementation results, verify expected benefits, document lessons learned, and establish controls that sustain the improved process.

Data Analysis & Performance Management

• Collect, organize, validate, and analyze manufacturing data using advanced Microsoft Excel capabilities and available ERP, production, and business systems.
• Develop clear reports, dashboards, and performance metrics that communicate operating conditions, trends, losses, and improvement opportunities.
• Support labor studies, staffing models, capacity planning, line balancing, productivity analysis, cost analysis, and internal or external process benchmarking.
• Analyze cycle time, setup time, queue time, work-in-process, downtime, scrap, rework, yield, schedule attainment, and other relevant measures.

 2.0 KEY RESPONSIBILITIES (CONTINUED)

Manufacturing Systems, Layout & Standardization

• Improve manufacturing layouts, workstation design, ergonomics, point-of-use storage, material presentation, and movement paths to support safe and efficient flow.
• Develop and maintain standard work, work instructions, visual controls, process documentation, and training materials for implemented improvements.
• Support accurate routings, labor standards, capacity assumptions, and other manufacturing-system data used for planning and performance evaluation.
• Evaluate tooling, equipment, fixtures, and appropriate automation opportunities; document requirements, operational impacts, risks, and expected returns.
• Support new-product introduction, process transfers, product-mix changes, and Engineer-to-Order workflow improvements by assessing capacity, sequence, labor, and material-flow needs.

Cross-Functional Collaboration & Change Leadership

• Conduct regular Gemba walks and engage directly with operators, supervisors, technicians, engineers, and department leaders to understand operating conditions and constraints.
• Facilitate focused Kaizen events, value stream mapping sessions, process-improvement workshops, and structured problem-solving meetings.
• Translate technical analysis into practical actions, visual information, and recommendations that are understandable to both production teams and leadership.
• Build stakeholder ownership by incorporating frontline expertise, clarifying responsibilities, and supporting adoption of new standards and systems.
• Maintain strong working relationships across departments and escalate barriers that require leadership decisions or additional resources.

Safety, Quality & Operational Discipline

• Integrate safety, ergonomic, quality, traceability, and compliance requirements into process designs and improvement recommendations.
• Partner with Quality and operational leaders to reduce defects, rework, process escapes, and variation without weakening required controls.
• Follow applicable change-control, document-control, equipment-approval, and training requirements before revised processes are released.
• Model safe behavior, follow required PPE and facility rules, and promptly report hazards, incidents, or conditions that could affect people or operations.

Professional Development

• Continue developing Industrial Engineering expertise through hands-on project work, mentorship, benchmarking, and formal learning.
• Expand capability in Lean Manufacturing, value stream mapping, statistical analysis, process optimization, and operational excellence methods.
• Progress toward leading larger, higher-impact, cross-functional initiatives as technical depth, business understanding, and influence grow.

Initial 12-Month Performance Outcomes

• Develop a thorough understanding of Spike Electric's manufacturing processes, product families, information flow, and key operational constraints.
• Complete current-state process maps and validated performance baselines for assigned manufacturing areas.
• Lead multiple improvement projects that deliver verified gains in productivity, quality, safety, cost, delivery, or throughput.
• Implement standard work and supporting documentation for improved processes and establish measures that confirm sustainment.
• Build effective working relationships with Production, Engineering, Supply Chain, Quality, Maintenance, and Operations stakeholders.
• Demonstrate the ability to independently identify, prioritize, and execute meaningful improvement opportunities and maintain a visible project pipeline.
• Obtain Six Sigma Green Belt certification if not already certified at the time of hire.

 3.0 QUALIFICATIONS

Required

• Bachelor's degree in Industrial Engineering, Manufacturing Engineering, or a related engineering discipline.
• Five to eight years of Industrial Engineering, Manufacturing Engineering, or process-improvement experience in a manufacturing environment.
• Demonstrated experience leading manufacturing process-improvement projects from planning through implementation and results verification.
• Working knowledge of Lean Manufacturing principles, continuous-improvement methods, and structured root-cause problem solving.
• Six Sigma Green Belt certification, or the ability to obtain certification within 12 months of hire.
• Experience performing time studies, workflow analysis, capacity or labor analysis, process mapping, and process documentation.
• Advanced proficiency with Microsoft Excel and the ability to organize, validate, analyze, and clearly communicate operational data.
• Ability to translate analytical findings into practical solutions that can be implemented and sustained in a production environment.
• Comfort working extensively on the manufacturing floor and collaborating directly with production personnel at all organizational levels.
• Strong written and verbal communication, facilitation, organization, project management, and analytical problem-solving skills.

Preferred

• Experience in a custom manufacturing or Engineer-to-Order environment.
• Experience facilitating value stream mapping, Kaizen events, 5S activities, and standardized-work development.
• Familiarity with ERP and manufacturing-planning systems; experience with Dynamics 365 Business Central is beneficial.
• Experience in switchgear, electrical equipment, control systems, or another discrete manufacturing environment.
• Experience developing visual management systems, production documentation, workstation layouts, and material-flow improvements.
• Familiarity with Power BI, Minitab, AutoCAD, simulation, or comparable analysis and layout tools.

Work Environment

• Work is performed across office and active manufacturing environments and requires frequent presence on the production floor.
• The role requires regular walking, standing, observation of work processes, and use of required personal protective equipment in designated areas.
• Occasional schedule flexibility may be required to observe or support operations, trials, or implementations outside normal business hours.

4.0 REPORTING STRUCTURE

Reports To: Director of Manufacturing Systems and Operations

• Operates as an individual contributor who may lead cross-functional project teams and coordinate the work of subject-matter experts without direct supervisory authority.
• Works closely with Production, Engineering, Supply Chain, Quality, Maintenance, Information Technology, Finance, and Operations leadership.

5.0 COMPENSATION & PAY BAND

Assigned Pay Grade: G-5TECH

Incentive Guideline: Per approved pay band governance

Specific salary ranges are defined separately in the controlled Spike Electric Pay Band Structure and are not published on this job description. Pay placement, incentive eligibility, payout, and metrics are governed by the applicable approved pay band and incentive plan and by company performance conditions.

6.0 DISCLAIMER

The statements above describe the general nature and level of work performed. They are not an exhaustive list of all responsibilities, duties, and skills required. Duties may evolve as needed to meet the organization's goals, and the employee may be required to perform tasks outside normal responsibilities to support the success of Spike Electric Controls.