Position Summary: The Industrial Program Engineer (IPE) will execute work package tasks and ensure their accomplishment with the support of the extended team and be accountable for Program related activities at the Plant.
IPE will provide operational support on key Industrial Development activities that are necessary for a successful product launch, contribute actively to the accomplishment of Industrial Development work packages throughout the program evolution and be involved in the approval process of Process Development activities upstream. IPE will actively participate in the execution of the Shape Launch Process, Shape Excellence System (SES), and Engineering Change Processes at the plant to ensure Customer Satisfaction, Production Readiness, and PPAP's on time. Act as a liaison between, business unit program teams and the plant operations team.
Position Skills and Experience Requirements:
To perform this job successfully, an individual must be able to perform each essential duty effectively. The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform essential job functions.
- Bachelor of Science in Engineering or Business Administration.
- Have at least 5 years experience in production, including methods & industrialization
- Ability to functionally work in a plant and program team
- Ability to communicate with the business unit program team, the plant, Experts (AME team), the equipment suppliers, etc ...
- Open-minded, driven by continuous improvement (Kaizen), fact & data (FRM) and shopfloor (gemba) mindsets
- Familiar with financial issues in programs (cost estimation, P&L, investments)
- Experience in equipment and Tooling Procurement.
- Long Term Planning and Problem-Solving Skills.
- Ability to effectively interact with team members and customers at all levels.
- Promote collaboration with internal and external customers at all levels
- Proficient with Microsoft Office applications.
- Proficient at problem solving using 4c methodology
- Ability to interpret and analyze technical procedures and customer specifications.
- Independent and organized work style: effectively manages time and prioritizes multiple tasks.
- Ability to create project plans and timelines based on input from other team members.
- Understand task dependencies and each task's potential to impact project timing.
- Prior experience managing or coaching less senior team members.
- Be able to travel as needed.
IPE is an active contribution to the accomplishment of all Industrial Development activities of the Program:
- Contribute to all Industrial Development work packages with a direct reporting line to the head of Industrial Development at the Plant: industrial footprint, Plant equipment selection (new / reuse / share), Plant layout, MIFD / MIFA, industrial trials...
- Participate in activities to ensure HSE and ergonomic convergence in the Plant
- Support the head of Industrial Development on the definition of the Industrial Development support team
1820 Hayes Avenue, Grand Haven, Michigan 49417
Essential Job Functions include, but not limited to, the following
- Represent the IPM & Plant Manager in all aspects of the launch organization and planning.
- Input and update the Program team in terms of Plant operational performance to align with the Business unit plan and production capacity
- Participate in a Tool kickoff (TKO) meeting in the early "Production Set-up & pre-series" phase of the program but no later than 6 months before SOP.
- Participate in Equipment Design Workshops and SES Equipment Design Cardboard Workshops
- Engage in the implementation of all relevant SES and Ergonomic principles (including the 20 SES Equipment Design guidelines) and SHAPE technical standards
- Aid in the build up of the final industrial footprint in line with Industrial Strategy;
- IPE is to actively contribute to the development of external & internal MIFA / MIFD. SES, SC&P & Plant Launch teams have to support IPE in the achievement of this work package, and SES is in charge of systematic validation.
- Precise share of work must be agreed between the industrial team members with the IPE at the beginning of the program in order to take into account corresponding costs in budget preparation.
- Support the staffing & training plan in close coordination with the IPM and Plant Manager
- Make sure that all industrial & logistics tasks & deliverables required by Shape launch system are carried out according the program schedule and participate actively to the Cross Functional Reviews.
- Check and take advantage of relevant lessons learned from similar programs;
- Collaborate with IPM to ensure that FMEA (Failure Mode and Effects Analysis) are done and followed, that the KCC (Keys Controls Characteristics) are well chosen, and the process & equipment capabilities targets are achieved;
- Make sure that any product modification will have no negative impact on the product manufacturing;
- Manage the first parts launch of production in plants, product & process tuning phases (in the pilot plant and in the plant), serial production trials including R@R (Run at Rate), MPT (Mass Production Trials), and EMPT (Extended Mass Production Trials), up to SOP or after if necessary.
- Ensure that the Launch Book and associated PDCA are launched on time, completed and updated run after run.
- Ongoing analysis of any type of industrial issues and risk, and initiate and lead the associated FRM and action plans (capacity, quality, respecting the CAPEX allowed, CAR control, security plans ...)
- Engagement with IPM to ensure that industrial performance KPIs are properly and permanently updated, improved and reported in Shape Launch reviews, CAR Committee, weekly then daily launch KPI published by plant, and look for any solution which could possibly improve them; main KPI are:
- work content & direct labor
- material yield
- layouts to set up the program in the plant,
- Industrial timing plan (tool & equipment follow up, including building if required)
- external & internal flows
- lead time and logistics costs
- 20 SES Equipment Design guidelines compliance
- Non Event Launch 7 Mandatory Rules
- Aid in implementation of all changes related to production system and/or related to the product (as of Engineering Change Management).
- Assist in all manufacturing program objectives in the plant (Safety, Quality, Costs, Delivery, Performance) such as Process and Machine Capabilities, cycle time, PPM, Scrap rate, on-time delivery.
- Participate in periodic manufacturing readiness review (MRR) between Plant & Program teams which would include identifying issues, assigning tasks and driving accountability.
- Communicate and report launch readiness progress
- Assures the plant receives all necessary support internally or externally to launch the product successfully.