We’re Hiring: Engineering & Process Improvement Manager
Join our operations team in beautiful Guntersville, AL as an Engineering & Process Improvement Manager! This is your opportunity to take on a career-defining leadership role where you’ll drive operational excellence, lead engineering initiatives, and strengthen training, quality, and process improvement across our operations.
As a family-owned, privately held U.S. manufacturer, we take pride in our people, our products, and our commitment to delivering unmatched quality and service.
We’re looking for a proven leader who’s ready to make a lasting impact:
✅ 10+ years of progressive engineering, manufacturing, or operations experience
✅ 5+ years in a leadership role
✅ Skilled in cross-functional process improvement and driving efficiency
If you’re ready to lead with impact and be part of a company that values collaboration, innovation, and excellence — apply today!
About Kappler:
For more than 45 years Kappler has defined the protective clothing industry with patented fabrics, innovative seaming technology and unique garment designs. All our critical protection chemical and biohazard suits are produced at our corporate headquarters in Guntersville, Alabama, providing American-made quality for added assurance. Registered to ISO 9001 since 1996, we document every detail when it comes to ensuring product quality. End-user safety is priority one, and our integrated manufacturing process is geared to making sure every garment meets demanding specifications. Whether it’s designing the most user-friendly suit possible or pressure-testing every gas-tight suit before it leaves the factory, Kappler quality comes through every time. From Berry-compliant products for DoD markets to NFPA-certified apparel for the most challenging hazmat calls, you know what you’re getting into with Kappler.
Engineering & Process Improvement Manager:
Summary/Objective:
The Engineering & Process Improvement Manager is responsible for leading the engineering function and driving operational excellence across Kappler’s production plant, warehouse, shipping & receiving, and cutting operations. In addition to managing engineering operations, including Standard Costing/BOMs/Routings, Production Floor Mechanics, and Quality Auditing, this position will own Kappler’s Operations Training Program – responsible for training new hires with zero production experience to upskilling experienced staff, ensuring consistent safety, quality, and skill standards.
The Engineering & Process Improvement Manager will be a strategic, hands-on leader who collaborates across departments and with external partners to enhance efficiency, reduce costs, and elevate product quality.
Key Responsibilities:
Engineering Leadership & Process Improvement
- Supervise and direct the work of Engineering staff, Production Mechanics, Production Trainers, and Quality Inspectors, ensuring alignment with company goals.
- Drive cross-functional process improvement initiatives across production, warehouse, shipping & receiving, and cutting operations to boost efficiency, lower costs, and elevate product quality.
- Continuously evaluate and refine manufacturing methods, implementing cost-saving modifications and leveraging semi-automation and automation technologies for operational excellence.
- Collaborate with Engineering staff to design and optimize manufacturing layouts, workflows, and ergonomics for new product lines, maximizing cost effectiveness and productivity.
- Lead targeted quality improvement projects by identifying root causes and defects and inefficiencies, ensuring consistent product excellence.
- Analyze workflows to uncover bottlenecks, implement corrective actions, and enhance throughput while minimizing waste.
- Monitor KPIs and deliver comprehensive reports to executive leadership on operational performance, cost savings, and project impact.
Product Quality
- Define, maintain, and continuously improve product quality standards and inspection protocols.
- Develop quality training programs for production employees to strengthen defect recognition and prevention.
- Lead root cause analysis and corrective/preventative action (CAPA) initiatives to reduce recurring defects.
- Analyze quality metrics (defect rates, first-pass yield, rework costs) to identify trends and drive improvements.
- Collaborate with Engineering staff and Operations leadership to implement process improvements that enhance consistency and reduce variability.
- Ensure compliance with customer requirements, regulatory standards, and internal specifications.
- Drive cross-functional accountability with Production Supervisor to prevent and quickly resolve on-hold situations. Verify rework for compliance before product release.
- Verify Quality Module in X3.
- Champion a culture of quality accountability and continuous improvement across the plant.
Operations Training Program
- Manage and continuously enhance the company’s Operations Training Program for new hires and existing employees, primarily in production, as well as warehouse, shipping & receiving, and cutting departments.
- Partner with department leaders across production, warehouse, shipping & receiving, and cutting, and human resources, to develop training content that aligns with operational demands and regulatory standards.
- Monitor training completion and effectiveness rigorously, using performance feedback and operational shifts to refine and adapt programs.
- Embed core principles of safety, quality, compliance, and accountability into every training initiative to foster a culture of ownership and excellence.
Other
- Plan and manage budgets, in conjunction with the Operations & Finance Director.
- Ensure a healthy and safe working environment, and compliance with federal and state regulations, through collaboration with Human Resources and safety personnel.
- Participate in recruitment, training, and development of employees, and ensure business continuity with succession planning. Conduct performance evaluations that are timely and constructive.
- Work onsite, in person to develop cross-departmental relationships and collaboration, maintain high levels of service and productivity, and be readily available to promptly address dynamic business needs as they arise.
- Perform other related duties as assigned.
Required Skills/Abilities:
- Excellent verbal and written communication skills, with the ability to present to executive leadership.
- Excellent supervisory and leadership skills, including effective delegation and mentoring.
- Strategic thinking with strong attention to detail.
- Excellent organizational, analytical, and problem-solving skills, including familiarity with statistical process control (SPC) tools and other analytical methods to collect and interpret data for decision making.
- Financial acumen and ability to analyze operational and financial data.
- Thorough understanding of company products and logistics.
- Ability to maintain confidentiality.
- Ability to manage and direct projects.
- Advanced knowledge of multiple safety industries, including Health & Safety, First Responders, Department of Defense, and Oil & Gas.
- Proficient with MRP and ERP systems, and Microsoft Office Suite.
Education & Experience:
- Bachelor’s Degree or higher in Engineering, Industrial Management, Operations, or related field strongly preferred; advanced degree preferred.
- Minimum 10 years of progressive engineering, manufacturing, or operations experience, with at least 5 years in a leadership role strongly preferred.
- Knowledge of basic accounting principles preferred.
- Experience in the apparel/textile industry strongly preferred.
- Familiarity with Lean (Kaizen), Six Sigma, or other continuous improvement methodologies strongly preferred.
Work Environment & Physical Demands:
- To perform this job successfully, an individual must be able to perform each essential job duty satisfactorily. Reasonable accommodation may be made to enable qualified individuals with disabilities to perform job functions.
- Must be able to stand, sit, and walk for prolonged periods of time; talk, hear, and use hands and fingers to operate computer and telephone keyboards.
- Noise levels are usually moderate.
- Ability to see and adjust; close vision and distance vision.
- Must be able to lift up to 25 pounds at a time.
- Occasional travel required.
Disclaimer: This job description is not designed to cover or contain a comprehensive listing of activities, duties, or responsibilities that are required by the employee. Kappler is an Equal Opportunity Employer, including disability.
