SummaryThe Manufacturing Engineer is responsible for process ownership, integration, and improvement of the assigned component part(s) and process. Demonstrate subject matter expertise to complete process improvements, designing effective operating instructions and implementing the best practices in a uniform manner across the manufacturing enterprise.
Focused on driving all safety, quality, productivity, schedule attainment, and yield maximization goals. Collaborate and partner with Program Engineering, Quality Engineering, Maintenance, and Plant Management Teams to continuously improve the manufacturing system through a combination of both engineering and operational excellence principles.
Lead multiple root cause and prevention initiatives including performing analysis of existing process parameters to improve workplace safety, first time product acceptance, product defect detection, decreased attention and throughput capabilities.
Incorporates design for safety and human factors into all process integrations and process improvements. Will work in teams, take direction, and produce sustainable results.
Wil perform all manufacturing engineering disciplines including FMEA, control plans, product quotes, process improvement, process design and integration, tooling/gauging/workstation design, training, and incorporate lean principles to maximized results.
Key Qualifications- Extensive experience in manufacturing engineering developing and improving manufacturing systems utilizing both engineering and lean principles.
- Ability to focus and generate the maximum results is mission-critical. Must understand how to use performance metrics to focus work efforts. Work results are expected to increase company performance metrics, decrease total cost, improve safety culture, and deliver an exceptional customer experience.
- A high degree of urgency to identify concerns and implement solutions is expected. Extensive background working on the shop floor with operators demonstrating urgency to solve key manufacturing problems that lead to high costs. Front-line collaboration with team members is essential to the position, and the ability to gain buy-in and trust is paramount to the role.
- Advanced technical ability in the areas of mechanics, pneumatics, cleaning, assembly, machining, presses, tooling, fixtures, gauges, material handling equipment, creating job instructions and completing stakeholder presentations is expected.
- Must practice and demonstrate superior communication. Must have the ability to communicate effectively with front-line team members, customers, and executives. Effective interpersonal and conflict resolution skills, with the ability to influence teams and program outcomes.
- Commitment to build and advance strong customer relationships.
Core Engineering Responsibilities- New Product Launch: process design, cost planning, budget creatin/management, capital approvals, machine specifications, project and supplier schedule management, equipment runoff and validation, control documentation development.
- Direct production line support, through CFT activity, for safety, quality, productivity and cost management: setup and utilize KPI measures to direct improvement actions, collaboration with QA department to plan, execute and document countermeasures for quality issues, manage process changes through planning, testing implmenetion and document revision, train produciton & maintenance members on new equipment/systems.
- Program Engineering Collaboration: receive program update, information, and instruction from Program Engineering Team to complete necessary remanufacturing process changes.
- Component and Process Expertise: demonstrate subject matter expertise on assigned component parts and each of the respective processes across the manufacturing enterprise. Will be the source for process knowledge and share / train best practices with operations team.
- Process Improvement: complete evaluations of component part manufacturing process at the workstation level and develop process improvements in the areas of tooling, part retention, fixtures, presses, gauges, and instrumentation. Operator collaboration is expected in all forms of process improvement.
- Operating Instructions / FMEA / Control Plan: design and complete all FMEA and Control Plan documentation to ensure Quality Management System (QMS) compliance. Translate desired assembly build outcomes into visual and clear operating instructions to ensure the process is completed safely while maintaining product quality and throughput speed.
- Best Practice Read Across: implement proven solutions across all common component and processes across the enterprise.
Engineering and Process Ownership Practices- Engages in daily process improvement with front line team members and supervisors as a best practice to evaluate, support, and sustain a robust process.
- Collaborates daily with Program Engineers to develop focused action plans and projects aimed at process improvement. Will also collaborate with Quality Engineering Team to develop action plans focused on total quality improvement.
- Translates and implements customer product specifications into financially sound manufacturing methods and processes. Responsible for process improvements and complete process re-designs when applicable. Demonstrate skill and efficiently in the areas of tooling, machine, and flow improvements all focused at decreasing total costs and driving throughout speed.
- Utilizes the operational excellence operating system as a fundamental tool to streamline production systems; working towards one-piece-flow, reducing work-in-process inventory, and sustaining process improvements with total productive maintenance.
- Identifies and develops improved tooling and inspection equipment to support operational goals. Reviews customer supplied BOM and develops an internal manufacturing BOM according to company standards. Directly interfaces with customer engineering resources to satisfy customer demand and quality goals.
- Prepares and submits new process change documentation and supervises new product validation plans to the customer for final approval (PPAP). Prepares and submits new process floor layout proposals and prepares such presentations for customer and leadership approval.
- Interfaces with business operations to coordinate launch of new products, based on new product launch and new product implementation timing goals. Troubleshoots operational capability, quality, capacity and equipment reliability problems and facilitates problem solving efforts to determine root cause and corrective actions.
- Prepares and submits methods for improving worker efficiency and reducing waste of materials and utilities such as: reorganizing work flow, relocating work stations and equipment, and the purchase of equipment. Analyzes business demands and develops forward looking capital spend plan planning documents
- Performs as a mentor and trainer to subordinate production and engineering staff. Provides regular status reports and updates to the Manufacturing Engineering Manager. Responsible for adherence to the policies, procedures, work rules and instructions of the IATF and internal Quality Management System as related to operations.
- Responsible for adherence to the policies, procedures, work rules and instructions of IATF 16949 systems as related to operations. Additionally, responsible for adherence to the policies, procedures, work rules and instructions ISO 14001 Environmental Management.
Education and Experience- A Bachelor's degree in engineering, business, technology, or physical science discipline and 5-10 years of proven manufacturing engineering experience driving process integration and process improvement.
- Must have proven experience leading and improving a manufacturing process working both independently and in teams. Must have practical knowledge of engineering mechanics, physics, hydraulics, electronics, pneumatics, machine design/operation, and computer software.
- A thorough understanding of the operational theory and principles of operation of automatic transmissions and internal combustion engines.
- 5+ years of experience with assembly of complex mechanical assemblies required.
- High level of analytical ability required, where problems are unusual and difficult.
- 5+ years of Lean manufacturing operational theory, principles and tools is required.
- 5+ years of experience prioritizing and assigning tasks, and accurately estimate the time and costs required for project completion.
- Experience in creating, developing, adapting, and communicating tool design concepts based on input from internal and external customers using advanced design tools (ACAD) and techniques a plus.
Language Skills- The ability to read and interpret manufacturing documents/drawings/prints/details such as safety rules, operating and maintenance instructions, machine drawings, wiring/electrical schematics, and repair manuals is required.
- Must write detailed reports with supporting documentation and data.
- Superior communication and escalation skills and habits are critical to the manufacturing engineering role; including customers, team member, and leadership communication.
Computer Skills- Must be proficient in the operation of computers, word processing, spreadsheet and database software and design software applications.
- Must be able to demonstrate the ability to develop written communication, spreadsheets, charts and graphs.
Mathematical Skills- Superior mathematical problem solving is paramount to the position. The ability to add and subtract, multiply and divide, in all units of measure, using whole numbers, common fractions and decimals is a requirement.
- Ability to compute rate, ratio and percent and possess the skills to develop and interpret graphs.
- Must utilize, comprehend and understanding statistical methods and the interpretation of statistical results
Reasoning- The position requires the ability to solve practical problems with limited known variables, in situations where only limited standardization exists. The ability to interpret a variety of instructions furnished in written, oral, diagram or schedule form is a requirement.
Critical Thinking and Problem Solving The position requires the ability to solve complex problems with limited known variables, in situations where only limited standardization exists. The ability to interpret a variety of instructions furnished in written, oral, diagram or schedule form is a requirement.
Physical demandsThe physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
While performing the duties of this job, the employee is regularly required to talk or hear. The employee frequently is required to stand; walk; use hands to finger, handle or feel; reach with hands and arms; stoop, kneel or crouch. The employee is occasionally required to sit. The employee must occasionally lift and/or move up to 30 pounds. Specific vision abilities required by this job include close vision and color vision, peripheral vision, depth perception and the ability to adjust focus.
Work EnvironmentThe work environment characteristics described here are representative of those an encounter while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
While performing the duties of this job, the employee is frequently exposed to moving mechanical parts, fumes or airborne particles and risk of electrical shock. The employee is occasionally exposed to vibration. The noise level in the work environment is usually moderate.
