Responsible for creating, supporting, and developing new and existing process designs related to manufacturing and fabrication processes. This is successfully accomplished by understanding, accurately specifying, and adhering to customer requirements, utilizing and applying quality tools and methods and pursuing continuous improvement in all aspects of product and process design. These efforts will have a direct impact on reducing labor and material costs, while improving value, reliability, and performance. The associate will plan and manage process and product related design and validation activities. This position reports to the Engineering Manager.
1.- Methods Improvement 25%
onduct work measurement studies to determine machine utilization, downtime, runtime, etc. using Industrial Engineering techniques such as stopwatch studies, work sampling, ratio-delay, predetermined times, and video tape-recording, in conducting studies for work measurement.
"Work with manufacturing engineers and product development engineers to create/develop manufacturing and fabrication methods for new or revised products. Evaluate all possible methods and determine optimal method that provides least cost, most efficient and safe methods to be used.
"Document methods with clear, well-written methods descriptions including photographs where applicable.
"Maintain departmental records on work measurement activity including standard numbers, department assigned, operation numbers, standard description, effective data, and quantity per year, net increase/decrease.
"Review work methods to assure that operations are being performed in a safe, efficient manner. Work with supervisors and group leaders to improve methods as necessary.
2.- Production Layout 10%
evelop layouts utilizing the following lean manufacturing principles:
oSet-up time reduction
oValue stream mapping
"Investigate activity-machine-relationship as a basis for machine, operations, department or plant-wide layout.
"Using activity relationship information provide layouts of work areas, departments, facilities and plants.
"Provide copies of layouts to management personnel and others as required.
"Conduct discussions, engages production associates, departmental manager, and other engineering members for all layout changes.
3.- Product and Process Specifications 25%
evelop and maintain process specifications to produce the highest level of quality throughout the entire component manufacturing / fabrication / assembly process.
"Determine the optimum process routing for components and products, producing the highest quality levels at the lowest cost and minimizing waste.
"Develop written procedures in the form of Standard Practice Instructions to specifically describe how to perform a required task and steps and tools necessary to complete that task.
"Establish procedures and systems to prevent the production of off-quality products
"Establish approval systems as a means of controlling process conditions, fabric routings, standard practices, and documentation of completed work assignments.
"Provide the cost accounting department and the industrial engineering department with necessary information to determine product costs and departmental cost standards.
4.- Problem Solving and Quality Improvement 20%
aintain an effective audit program for feedback to production managers, engineering, and quality assurance. Communicate how well process specifications are being followed, the capability of controlling process variables, and the maintenance condition of the equipment.
"Provide technical service to all departments to resolve quality related problems.
"Assist in the training and education of hourly, supervisory and management associates as required.
"Work with current suppliers to develop and improve existing products and processes, striving to reduce cost and minimize waste.
"Develop and maintain process control testing procedures for work-in-process to eliminate any off-quality performance.
5.- New Product Introduction 15%
ork with product development engineers to determine the optimum process routing and conditions for new products.
"Assist product development engineers in monitoring the quality and manufacturability of components and finished product in each production department.
"Work with facilities planning to define plant space needs concerning equipment and its functionality.
"Conduct plant evaluations of new equipment to determine performance levels in the areas of quality, safety, maintenance and cost.
"Prior to starting up a newly installed piece of equipment, work with manufacturing engineering, provide a safety inspection, and provide preliminary operating conditions to the production area.
"Work with suppliers in developing and improving new products and processes while reducing costs.
"Coordinate trials and evaluations of new products to ensure manufacturability, quality, and performance. Document results.
6.- Administration and Other 5%
ocument in writing all projects, studies, and work assignments and outcomes to provide accurate and complete information for future reference.
"Stay abreast of all current and new technology in industry. Review trade magazines and periodicals, attend technical conferences, and meet with supplier technical reps.
"Continuously work toward automating manufacturing processes and monitoring results through automation.
"As required, maintain records in an orderly fashion and analyze production and/or quality data as appropriate. Provide regular reports to stakeholders as appropriate.
Quality - (Required for all SWF job descriptions) - Integrates quality at the source thinking and activities in daily, individual, team and project work. (Applies to all job duties 100%)
1.Utilizes quality/process tools and methodology in daily individual work
2.Utilizes quality/process tools and methodology on teams
3.Defines and documents individual processes within sphere of control
4.Ensures that others are trained as back-ups on (processes) within the area/department
5.Improves processes within sphere of control
6.Identifies waste and rework and enacts plan to improve/solve
7.Checks satisfaction of internal customers through use of quality tools and Customer/Supplier metrics.
Scope of Responsibility:
"Responsible for developing and continuously improving component manufacturing and finished product fabrication processes at business locations. May have specific responsibility for component processes (metal finishing, wood finishing, extrusion, molding), which are used to in manufacturing products for the business.
"Organize and implement significant cost and efficiency improvements ($12-15M annually) within manufacturing environment by deploying continuous process improvement and optimization techniques utilizing known methodologies such as (TPS), Lean Manufacturing, and Six Sigma.
Education and Experience:
Minimum - Bachelor's degree; 7-10 years relevant experience
Preferred - Bachelors degree required in Mechanical Engineering, Industrial Engineering, or Manufacturing Engineering with strong industrial experience as a Process Engineer; Minimum of 7-10 years of practical manufacturing and engineering experience in designing and improving manufacturing processes.
Knowledge, Skills and Abilities:
Must be flexible with job assignments, able to work independently and well with others (team environment). Must be organized, methodical, and handle multiple tasks simultaneously and work to an established timeline. Position takes direction from Senior Process Engineer and/or Engineering Manager. Must manage multiple medium or large scope projects, Must communicate well and properly document results of test procedures, and have knowledge of SWF 5S Program.
•Data collection and management of database.
•Technical writing skills for memos, lab reports, and project updates.
•Strong general math skills (add, subtract, multiply, divide, percentages, fractions, metric conversions, algebra, and geometry)
•Good interpersonal skills
•Good analytical and problem solving skills including statistical analysis.
•Good communication skills (verbal, written)
•General computer skills Excel, MS Word, Lotus Notes, MS Project and Access
•Frontier System inventory (FRN)
•Preparing Samples for Testing and Analysis
•Familiarity with Springs products and processes
•In depth knowledge of various manufacturing processes as they are used in the manufacture of window treatment products.
•Manage work according to established project timelines.
•Knowledge and application of engineering principles.
•Strong software skills in spreadsheets, word processing, presentation software, and CAD.
•Mechanical aptitude and dexterity is required to work around machines safely and effectively.
•Creativity is required to develop new processes and solutions in a timely fashion.
•Must be experienced with continuous improvement methodologies such as Toyota Production System (TPS), Lean Manufacturing, and Six Sigma.
Quality - (Required for all SWF job descriptions)
1.Uses project plan and project schedule methodology
2.Clearly defines and utilizes processes in daily work
3.Knows SFW team structure, roles and responsibilities
4.Integrates process methodology into daily work; MPI, QAT, 5S, 6D, Q@S etc
5.Looks for innovative ways to streamline work processes across the division and involves stakeholders
6.Identifies gaps using tools such as Bald ridge criteria, WI Forward Award criteria, GPTW, IDP etc
7.Establishes forums to share best practices
8.Uses dept and company scorecard and other metrics
9.Measures own work to plan and reports out at a micro and macro level