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Engineering Specialist-Process

Engineering Specialist-Process

Ford MotorPretoria, Gauteng, South Africa
17 days ago
Job description

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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    Engineering • Pretoria, Gauteng, South Africa

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