Position is responsible for the process development of mechanical components, assemblies, and systems for new and existing products. Evaluates and troubleshoots manufacturing process issues with customer and in-house projects. Leads process FMEA activities and collaborates with the cross-functional team to ensure design for manufacturability and design for assembly is considered for each project.
Major Responsibilities – reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions:
· Lead in the development, design and validation of existing and new manufacturing and assembly processes utilizing 3D solid-modeling, CAD and FEA with a focus on employee safety, ergonomics, and lean concepts. Development should include consideration for direct labor differing language and skill capabilities.
· Follow the NPI Stage Gate process by executing the following:
o Ensure manufacturing process accommodates final machining to achieve geometrical tolerances.
o Determine manufacturing method and estimate setup/run times. (takt time/cycle time analysis)
o Develop control plans and inspection methods.
o Define all materials, tooling, fixturing, adhesives, methods of manufacturing, etc needed and ensure safety and quality are taken into consideration.
o Create high quality standard work that reduces human error.
o Apply GD&T as required to designs, and components drawings.
· Works effectively with CNC programmers and machine operators to develop manufacturing processes
· Work with all affected areas on safety observations, PFMEA, cost reductions, ECR’s/ECN’s, DMR’s and part obsolescence.
· Improve productivity, efficiency, safety and throughput while eliminating waste by continuously improving designs, fixturing and processes.
· Communicate with and provide manufacturing expertise to; Suppliers, Customers, Design Engineering, Quality, Operations, Purchasing, and Sales.
· Work to meet your personal and department engineering KPIs. Monthly, investigate and provide root cause analysis when KPIs are not met. Implement approved corrective actions.
· Perform other duties as required.
· Analyze and design detailed fixturing to reduce safety risk, improve quality and error proof the process.
· Assigned to multiple medium / complex NPI projects and projects for key customers. (Build to Print + / Dexter Design)
· Assists with reviews of customer and in-house prints and designs.
· Troubleshooter for major manufacturing and quality problems.
· Assists in the training and technical development of colleagues in other functions.
Salary Range: $110,000-$125,000 depending on experience
Education and Experience
· Bachelor’s degree in Industrial, Manufacturing, Mechanical Engineering preferred or equivalent combination of education and experience.
· Knowledge of magnetic materials and applications a plus.
· Minimum of 3 years playing a lead role in the manufacturing environment. Proven record of successful launch as it relates to new process introduction and planning efficient manufacturing processes.
· Proven record of managing cost reduction and continuous improvement initiatives.
· Strong 3D CAD skills, at least 2,000 hours of experience on Solidworks, ProE or other 3D package
· Strong drafting and GD & T skills with the ability to perform tolerance stack up analysis.
· Green belt/Lean Certification preferred.
Knowledge/Skills/Abilities
· Expert in Planning Manufacturing Processes
· Proven ability to Solve Manufacturing Problems and Complete RCCAs
· Advanced 3D CAD Skills - Solidworks Preferred
· Communications Skills in Verbal, Written, and Electronic Methods
· Advanced Understanding and Application of Quality Concepts (Six Sigma Green Belt Preferred)
· Advanced Understanding of GD & T