• Manufacturing Process Engineer

    Job Locations US-WI-MIDDLETON
    Requisition ID
    # of Positions
  • Description

    Job Purpose 

    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 Senior Manufacturing Manager.


    Job Duties 

    * Methods Improvement 35%

    • Conduct work measurement studies to determine overall equipment effectiveness 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.
      • Design new fixtures and equipment to facility process improvements.
      • Manage multiple capital projects from selection through implementation.

    * Problem Solving and Quality Improvement 30%

      • Maintain 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.

    * Product and Process Specifications 10%


      • Develop 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.

    * New Product Introduction 10%

      • Work 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.

    * Production Layout 10%

      • Develop layouts utilizing the following lean manufacturing principles:
        • Set-up time reduction
        • Visual management
        • Kanban/pull systems
        • One-piece flow
        • Value stream mapping
        • Cellular Manufacturing
      • 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.

    * Administration and Other 5%

      • Document 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. 


    Education and Experience
    * Bachelor's degree required 

    * Minimum 3 years of relevant experience 

    * Preferred - Bachelor's degree in Mechanical Engineering, Industrial Engineering, or Manufacturing Engineering with strong industrial experience as a Process Engineer;

    * Preferred - 7+ years of practical manufacturing and engineering experience in designing and improving manufacturing processes. 

    * Injection molding experience required

    * Capital project management experience required 

    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 Manufacturing Manager.

    * Must manage multiple medium or large scope projects

    * Must communicate well and properly document results of test procedures, and gain knowledge of SWF 6S 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)

    * Technical Writing

    * General computer skills Excel, MS Word, Lotus Notes, MS Project and Access

    * Preparing Samples for Testing and Analysis

    * Familiarity with Springs products and processes 

    * In depth knowledge of various manufacturing processes

    * 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. 


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