Overview
Description
ROLE SUMMARY
The Engineering Specialist Process : Leads Manufacturing Process Engineering for Final Assembly (Trim / Chassis) driving continuous improvement in safety, quality and productivity. This role is central to program launch management and readiness overseeing all aspects from initial planning to production.
Responsibilities
- Lead Manufacturing Process Engineering activities for Final Assembly with a focus on Trim and Chassis Assembly operations.
- Drive continuous improvement in safety, quality and productivity across all manufacturing processes.
- Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products.
- Develop action plans to investigate and prioritize quality concerns and verify corrective actions on internal processes and supplier processes.
- Conduct process audits to ensure process discipline consistent with Vehicle Operations guidelines, adherence to process outline and drive continuous improvement.
- Conduct job ergonomic evaluations and deliver corrective actions as required.
- Analyse vehicle inventory root causes; engage in mapping and corrective actions to reduce vehicle inventory.
- Deliver capable processes and tools for Trim and Chassis Assembly operations.
- Lead in resolving assembly-related concerns; lead variability reduction and lean manufacturing initiatives and best practices.
- Identify throughput constraints and drive root cause improvements.
- Identify and drive to closure all FRC issues within Chassis and / or Trim areas.
- Maintain fixture / jig integrity within your responsible zone along with required backups.
- Identify and close all control plan items marked as red within your respective zones.
- Support MTC changes and efficiency activities within Chassis and / or Trim areas.
- Support warranty investigations in Chassis and / or Trim areas.
Program Launch Management & Readiness
Confirm layouts, material flow diagrams, and pedestrian flow meet standards for new programs.Ensure new parts are plotted and will fit on the station and layout demarcations meet layout standards (CLL).Support all aspects of build events (Slow Build, TT, PP, MP1, FCPA, FER) including leading war room meetings, capturing and binning build issues, ensuring robust 8D / 5D / 4D closure actions and sending quality scorecards and night letters.Review changes in product and process that may impact the plant manufacturing process or operational plan delivering programs within current model constraints.Conduct content change analysis with the launch team to understand impact on processes and facilities, ensuring countermeasures and training are implemented.Ensure Zoning is completed prior to all GDPS milestones with no new launch-related open issues and ensure carry-over items are moved to DCC or MCC for the department.Lead the Workstation Readiness Assessment (WSR) as per standard, ensuring zero open issues and that the WSR is followed three weeks before every build phase.Ensure Part sign-off prior to build phase for all Non-PPAP parts and coordinate with MP&L to isolate launch parts, preventing damages.Quality Operating Systems (QOS) & Compliance
Ensure Plant QOS processes are active and complete, covering gauging strategy, equipment capability, traceability, DCP, OIS, WES, QCM, error-proofing systems and inspection processes.Ensure correct measurement system / gauge selection, Gauge R&R study completion, functional QLS systems, and calibration of DC tools and bench calibration.Update QCM in line with new content and ensure all control plan items are implemented and validated during build; keep OIS / WES up to date for Launch APT plan.Review High Hurts Matrix and ensure previous issues are validated and handed over to the team; support Whiteboard meetings to ensure ICA / PCA within 24 hours.Incorporate teardown results and test results corrective actions into manufacturing and N End-of-Line testing processes.Safety Health & Environmental Compliance
Complete risk assessments for design, build, modification and commissioning of equipment; ensure Pre Task Assessments are signed off for skilled trades / contractor work.Support PROTAG sign-off to guide plant personnel through White-to-Pink, Pink-to-Yellow and Yellow-to-Green phases; review PROTAG status and punch list completion.Ensure signage in work areas identifies hazards; manage chemical hazard information as per procedures and ensure proper loading / labeling.Ensure Job Safety Analysis (JSA) is completed for processes prior to TT build.Ensure Backup tooling is available per BBQ strategy; comply with Plant Corporate, Governmental and Environmental standards; support ISO 14001 compliance and internal ISO auditing as required.Ensure safe and proper disposal of equipment; minimize power consumption when idle; follow handling, cleaning and corrosion protection of metal parts.Cost Initiatives
Lead one cost-saving project to implementation per year.Implement one Kaizen project per month.Communication & Collaboration
This role requires extensive collaboration and communication with Manufacturing Leadership, Quality, Production, Maintenance, LPWR, Product Development, Vehicle Manufacturing Engineering (VME), external suppliers and cross-functional teams to ensure seamless operations and successful program launches.
Performance Measures / Success Criteria
Implement Zero Defect / Error Proofed Processes.No downtime related to jig / fixtures within Chassis and / or Trim areas.Deliver a zone FRC greater than 97%.Ensure process audits are conducted within specified timing as per company policy.Complete a minimum of two Green Belt projects per year.Within two years of enrolment, Green Belt certification.Layouts material flow diagrams and pedestrian flow meet standards.Risk assessments completed for design / build modification and commissioning of equipment.Pre-Task Assessments signed off for skilled trades / contractor work.PROTAG sign-off supported to plan and punch list items followed to completion.JSA completed for processes prior to TT build.Robust 8D / 5D / 4D closure actions for build issues.Plant QOS processes active and complete; all required documentation and calibration are maintained.High Hurts Matrix reviewed and updated.All production quality requirements maintained during build phase.Whiteboard AIMs and build issue management ensure ICA / PCA are in place.Build Quality Metrics for each build milestone.Teardown results and test corrections incorporated.Program delivered within model constraints with content analysis complete.Zoning completed prior to GDPS milestones with no new launch-related open issues.WSR completed with zero open issues prior to GDPS milestones.Part sign-off prior to build phase for all Non-PPAP parts completed.Cost-saving and Kaizen projects implemented.BBQ and backup tooling available; equipment power consumption minimized.Knowledge, Skills and Abilities (KSA)
Technical Skills :
Lean Manufacturing and Six Sigma experience.8D and 5Why corrective action and problem-solving skills.Lean Tools : 5S, Kanban, Poka-yoke, Value Stream Mapping.DMAIC and DMADV project methodology experience.TQM and Kaizen methods.FMEA, PPAP and DOEs experience.Ergonomic analysis knowledge and experience.GSPAS / APT; CLL / Auto CAD; WERS; MOVIS AIS.Knowledge of Plant Layout, Material Flow Diagrams, Pedestrian Flow standards.Risk Assessment methodologies and PROTAG procedures.Chemical Hazard Communication Standard and TOX number management.Job Safety Analysis (JSA).QOS processes including gauging, traceability, and calibration.Experience with Production FIS / IIoT systems.Build event management and related procedures.WSR and LPWR processes and eFPS.Competencies :
Effective oral and written communication skills.Strong leadership and teamwork abilities.Problem-solving and analytical thinking (8D / 5Why).Ability to drive continuous improvement and lean manufacturing.Strong organizational and planning skills; results-oriented with KPI focus.Collaborative across diverse teams; proactive in addressing challenges.Qualifications
Qualifications and Experience
Preferred Requirements : Education : Bachelor's degree in Mechanical, Electrical or Industrial engineering.Experience : 5 years of related experience.Green Belt certification is an advantage.Ariba access is an advantage; leadership in ONE FORD behaviors.Required Experience : Unclear Seniority
Key Skills : Hr Executive Recruitment, Internship, Information Technology Sales, Furniture, Administration Support
Employment Type : Full-Time
Department / Functional Area : Manufacturing
Experience : years
Vacancy : 1
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