Senior Process Engineering Manager

Katerra   •  

Phoenix, AZ

Industry: Manufacturing & Automotive

  •  

11 - 15 years

Posted 51 days ago

One of KATERRA 's cultural principles is Diversity. We believe different backgrounds, ideas, and skillsets result in better outcomes. KATERRA does not discriminate in employment based on race, color, creed, national origin, ancestry, sex, marital status, disability, religious or political affiliation, age, sexual orientation, or gender identity. KATERRA encourages people of all backgrounds to apply, including people of color, immigrants, refugees, women, LGBTQIA, people with disabilities, veterans and those with diverse life experiences.

Senior Process Engineering Manager

KATERRA 's Phoenix Factory is seeking a Process Engineering Manager who will be responsible for driving continuous improvement within manufacturing and supporting departments. The manager reviews product and process flows, plant layout, operation procedures, equipment utilization etc., in conjunction with process engineers and apply lean manufacturing techniques in order to identify, document, recommend and implement changes aimed at improving overall manufacturing efficiency. The manager will collaborate with the internal quality group to establish a sustainable "Change Control" system in the factory. Where ever applicable, the manager will leverage the knowledge gain from such activities as a "blueprint" for starting up subsequent KATERRA Manufacturing Sites' manufacturing operations.

Essential Duties & Responsibilities

  • Lead a team of engineers and technicians of various sub-factories within the Phoenix factory – wall, floor, cabinet, window, roof, & counter production
  • Ensure Implementation and sustaining of manufacturing processes and equipment that produce components for the construction industry; roof trusses, floor trusses and enclosed floor / ceiling components, enclosed interior and exterior wall components, countertops, cabinets, plumbing, window installation and cross laminated timber
  • Ensure designs are compliant with the company's principles of design for manufacturing, assembly, and systems integration
  • Ensure collection & analysis of manufacturing data to assess overall equipment efficiency (OEE)
  • Drive the identification and implementation of efficiency enhancing programs
  • Collaborate with the Quality Group to implement and drive sustainment of a "change control" system throughout manufacturing including document control and equipment changes and upgrades
  • Implement and sustain SPC as necessary (where applicable)
  • As needed, develop "new" manufacturing processes by studying product requirements; researching, designing, modifying, and testing manufacturing methods and equipment; collaborating with equipment vendors
  • Ensure generation of Work Instructions (WI) as needed to ensure manufacturing consistency
  • Improves manufacturing process efficiency by analyzing and planning work flow, space requirements, and equipment layout through Value Stream Mapping and other lean manufacturing techniques
  • Optimizes manufacturing processes to ensure the highest levels of product quality, manufacturing lead-times reductions and lowest cost manufacturing techniques through the use of lean manufacturing tools; 6S, Kaizens, Six Sigma and Total Quality Management applications as applicable
  • Support the conversion of small-scale processes into commercially viable large-scale operations
  • Monitors and improve the safety, output and efficiency of manufacturing processes through the measurement of key process indicators (KPI's) in support of the overall organization
  • Supports the company's strategic initiatives through the establishment of long-term process and equipment roadmaps
  • Audit manufacturing floor to ensure ongoing compliance to written documentation
  • Prepare reports, technical memorandums, and recommendations

Required Skills & Experience

  • Bachelor's degree in construction, mechanical engineering or related technical field
  • 10 years of experience in process engineering
  • 5 years experience in a leadership role
  • 10 years of experience in system integration and process development in manufacturing environments
  • Project Management experience is preferred
  • Experience with new product introductions (NPI) and transfer
  • Experience with lean & six sigma processes
  • Forward thinking with strong interpersonal skills are a must.

Expectations/Measurement

Success is measured by the engineering department's overall effectiveness in achieving set goals for their focus areas which includes:

  • Performance: On-time completion of assigned tasks (PAS). Achieving the expected output gains (actual vs plan)
  • Quality: Area yield (good unit count/total unit count), rework rate, defect repeat rate
  • Problem Solving: Identifying, taking ownership and solving problems in a timely manner as measured by documentation which defines the problem(s), proposed solutions, implementation process and validation
  • Teamwork: Ability to work effectively in a "team" environment as measured by team members and customer feedback