Process Engineer

General Scope of Responsibility : Manages the engineering planning & preparation activities necessary to launch assigned new jobs and engineering changes at rate and 100% quality.

Also, has engineering responsibility for resolving process problems and improving plant safety, quality, and productivity on assigned programs / processes.

DUTIES & ELEMENTS :

Executes the RVP process engineering activities

• Develops, optimizes, documents and updates process work instructions and set-up procedures as required.
• Develops and updates tooling specifications and best practices for plant processes.
• Reviews new and existing product design to ensure optimal manufacturability, adherence to tolerance guidelines, functionality, tool design, machine design, cell layout, and safety and ergonomic concerns.
• Leads process development effort through cross-functional teams to develop optimal cell layout and process flow layout while adhering to safety, quality, and productivity protocols.
• Develops, documents and employs process troubleshooting guidelines.
• Demonstrates compliance to department IATF 16949 : 2016 procedures.
• Participate in the TFC process to assist in determining optimum processes, tooling, and material requirements for customer quotes.
• Apply Lean manufacturing principles (e.g. 5S, value stream mapping, SMED, standardized work methods, etc.) to improve assigned processes.

Leads RVP Engineering efforts to resolve / improve process opportunities :

Identifies and resolves process improvements leading to better cycle times, reduced spoilage, improved process capability (i.

e. Cpk, Ppk), and increased throughput.

• Evaluates and takes actions needed to meet or exceed plant targets set for spoilage, cycle time, and quality.
• Assists production staff as process expert by utilizing troubleshooting, diagnosis, debugging, and other technical skills to keep production lines running at peak efficiency.
• Performs cause analysis and corrective action implementation on assigned customer complaints or internal failures as assigned
• Performs safety analysis and implementation as assigned.

Plant Launches / APQP activities

• Ensure compliance and complete assigned APQP activities
• Evaluate effectiveness of proposed process (process / flow / floor space / layout / ergonomics / etc.)
• Initiate activities to secure and install new equipment or processes.
• Leads cross-functional teams to develop PFMEA’s, mistake / error proofing.
• Leads and / or assists with tooling design and development from prototype through manufacturing production stages as required by Program Manager.
• Review product design with respect to materials, quality, function and manufacturability.
• Prototype and pre-launch production runs
• Train operators, supervisors, and maintenance personnel to run new processes and equipment.
• Ensure products meet quoted cycle time, material usage, and operator requirements.
• Coordinates PPAP, PSA’s, Run at Rates runs with plant personnel to ensure a capable product.
• The above statements are intended to describe the essential functions and related requirements of persons assigned to this job.

They are not intended as an exhaustive list of all job duties, responsibilities and requirements

QUALIFICATIONS (Education, Work Experience, etc.) :

Minimum Must have to be considered for the position :

• Bachelor’s degree in Engineering (Mechanical, Chemical, Electrical, or Industrial).
• Experience or training using computer software applications (MS Office, Windows Operating Systems).
• Demonstrated achievements requiring Mechanical / Electrical problem-solving and creative abilities.

Desired Will provide job holder with added skills(s) to perform duties :

• Five or more years relevant work experience in manufacturing involving automation applications.
• Experience interpreting or using CAD / CAM drawings and systems.
• A working knowledge of plant processes.
• The ability to perform Failure Model and Effects Analysis (FMEA) and Design of Experiments (DOE’s).
• A thorough knowledge of automotive policies and procedures, with emphasis on manufacturing planning, quality planning, statistical methods and problem solving.
• A demonstrated ability to plan and organize.
• The ability to reach closure on assigned tasks within suspense dates.
• Intermediate knowledge of Fanuc Robots

Physical requirements :

Occasionally ascends / descends ladders or stairs on manufacturing equipment to assist with trial runs. Must be able to lift parts weighing up to 50 pounds across plant floor when assisting in tool launch process.

Must be able to walk through the manufacturing plant and stand for long periods of time. Moving self in different positions to accomplish tasks in various environments including tight and confined spaces.

HUMAN RELATIONS :

Process Engineers work closely with, and often serve as support to, a number of different departments and personnel. As a result, and in order to achieve optimum effectiveness, they must maintain a positive, cooperative relationship with these various departments / individuals.

They must also be responsive to their needs.

Process Engineers interact with all levels of the organization, i.e., with operators through senior managers. To be effective, they must be sensitive to, and cooperatively blend the needs and goals of these various levels with the common denominator of achieving organizational objectives (i.

e., effective launches, safety, quality, productivity, cost reduction, and positive employee / employer relations).

Finally, in the role of a problem solver, Process Engineers must remain objective and be able to make recommendations based on facts, regardless of whether those recommendations are popular.