Caroline Lewis
Business Process Improvement Specialist
Caroline brings a practical, people-centered approach to Lean Six Sigma, combining her specialty chemical engineering background and hands-on manufacturing experience with a focus on organizational improvement. Her experience leading improvement projects and mill-wide Lean implementation, along with her work coaching teams and facilitating Kaizen events, reflects her commitment to developing people, improving performance, and building lasting cultures of collaboration and continuous improvement.
Areas of Expertise
Lean Six Sigma Methodologies
Applying Lean Six Sigma methodologies and structured problem-solving approaches to address process challenges and drive performance improvements.
Data-Based Decision Making & Statistical Analysis
Applying statistical methods to understand process performance and variation, support data-driven decisions, and monitor manufacturing processes through statistical process control.
Lean Culture & Workforce Development
Building a culture of continuous improvement through people development, coaching, and respect for everyone, helping organizations embrace Lean as a mindset and a way of working.
Scope of Experience
Caroline is an experienced engineer in the pulp and paper industry. Her career has been focused on improving operational performance through Lean Six Sigma and continuous improvement. She has worked closely with production and maintenance teams to improve paper quality and consistency, as well as equipment reliability and uptime. Her experience includes collaborating with operators, engineers, mechanics, and management; leading cross-functional teams through major quality improvement initiatives; and leading mill-wide Lean Six Sigma implementation through training, project deployment, coaching, and the development of a continuous improvement culture.
Through TMAC, Caroline has begun expanding her experience across a variety of industries and manufacturing facilities, delivering Kaizen events and coaching teams in their continuous improvement efforts.
Relevant Assignments
Lean Six Sigma Project Leadership: Led DMAIC projects to address manufacturing challenges and improve operational performance. Projects included improving paper strength by 34%, enhancing product quality and consistency, and delivering significant annual chemical cost reductions.
Mill-Wide Lean Six Sigma Implementation: Led the implementation of a Lean Six Sigma program across an entire paper manufacturing facility, including training, project deployment, coaching, and developing a culture of collaboration and continuous improvement.
Kaizen and Continuous Improvement: Supports and co-facilitates Kaizen events across a variety of industries and manufacturing facilities through TMAC, working with cross-functional teams to identify opportunities, solve problems, and implement improvements.
Education and Training
Caroline Lewis earned a Bachelor of Science degree in Paper Science & Engineering from North Carolina State University, a specialized chemical engineering degree focused on the pulp and paper industry.
Caroline is a certified Lean Six Sigma Black Belt, having earned her certification through TMAC while working in the paper manufacturing industry.
Honors and Awards
Caroline led a project that was recognized with the “Best Executed Project” award among 22 mill sites at her former employer.
Before beginning her technical career, Caroline was an All-American Track and Field athlete at NC State University. She was also recognized as a Top Scholar Athlete and earned a place on the ACC Academic Honor Roll.
Previous Employers
Caroline spent three years with Smurfit Westrock as a Process Engineer, specializing in data analytics and continuous improvement at the company’s facility in Forney, Texas.
Before graduating from North Carolina State University, Caroline completed internships across several areas of the paper industry, including paper manufacturing with New-Indy Containerboard, chemical supply with Solenis, and advanced analytics with Braincube.
