Our client is seeking a highly experienced and visionary Principal Industrial Engineer to lead process improvement initiatives and drive operational excellence within their advanced manufacturing facilities. This on-site role, located in Washington, D.C., US , is critical for optimizing production systems, enhancing efficiency, and implementing innovative engineering solutions. The Principal Industrial Engineer will be responsible for applying advanced engineering principles to analyze complex operational challenges, design and implement strategic improvements, and mentor junior engineering staff. This position requires a deep understanding of lean manufacturing principles,Six Sigma methodologies, supply chain optimization, and advanced simulation techniques.

Key Responsibilities:

Lead the analysis, design, and implementation of complex industrial engineering projects to optimize manufacturing processes, workflow, and layouts. Apply advanced lean manufacturing and Six Sigma methodologies to identify and eliminate waste, reduce costs, and improve product quality and throughput. Develop and utilize simulation models to analyze production systems, evaluate process changes, and predict performance outcomes. Design and implement optimal material handling systems, production scheduling, and capacity planning strategies. Collaborate with cross-functional teams, including operations, quality, supply chain, and product development, to integrate engineering solutions. Develop and maintain comprehensive standard operating procedures (SOPs) and work instructions. Lead root cause analysis for production inefficiencies and quality issues, implementing corrective and preventive actions. Define key performance indicators (KPIs) and establish monitoring systems to track operational performance. Oversee and mentor a team of industrial engineers and technicians, providing technical guidance and professional development. Stay current with emerging technologies and industry best practices in industrial engineering and manufacturing. Manage project timelines, budgets, and resources effectively. Prepare detailed technical reports, presentations, and business cases for proposed engineering projects. Champion a culture of continuous improvement and operational excellence throughout the organization. Ensure compliance with safety regulations and environmental standards in all engineered solutions.

Qualifications

Master's degree in Industrial Engineering, Manufacturing Engineering, or a related field. A Ph.D. is a plus. Professional Engineer (PE) license or Certified Lean Professional/Six Sigma Master Black Belt certification is highly desirable. Minimum of 10 years of progressive experience in industrial engineering, with a strong focus on manufacturing environments. Demonstrated expertise in lean manufacturing, Six Sigma, process optimization, and simulation modeling (e.g., Arena, AnyLogic). Proven track record of successfully leading and implementing large-scale process improvement projects. Excellent analytical, problem-solving, and critical thinking skills. Strong leadership, team management, and mentoring abilities. Exceptional communication, presentation, and interpersonal skills, with the ability to influence stakeholders at all levels. Proficiency in CAD software, ERP systems, and statistical analysis tools. In-depth knowledge of supply chain management and operations research principles. Ability to work effectively in a complex, dynamic, and fast-paced environment.