Manufacturing Process Engineer

Process Engineer

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.

Job duties include:

1. Methods Improvement 25%

Conduct 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.

Work with manufacturing engineers and product development engineers to develop new products, improve existing products, and implement 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 work instructions 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 and train associates as necessary.

2. Production Layout 5%

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.

3. Product and Process Specifications 20%

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.

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 15%

Lead or participate in specific quality improvement projects identified by quality manager and/or engineering manager.

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 while reducing cost and minimizing waste.

Develop and maintain process control testing procedures for work-in-process to eliminate any off-quality performance.

5. 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 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. New Equipment and Process Implementation 10%

Continuously work toward automating manufacturing processes and monitoring results through automation.

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.

7. Maintenance Supervision 10%

Supervise the daily activities of maintenance department, including 3-5 maintenance technicians and custodial staff.

Supervise the installation, maintenance, adjustment, and modification (when required) of manufacturing and supporting equipment throughout the facility.

Create, implement, and ensure compliance with preventative maintenance schedules for key equipment.

Maintain adequate inventory of consumable supplies and spare parts for key equipment.

8. 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.

As required, maintain records in an orderly fashion and analyze production and/or quality data as appropriate. Provide regular reports to stakeholders as appropriate.

Compile and report weekly and monthly metrics data and attend meetings/conference calls for reporting purposes as required.

Maintain personnel records for direct reports as necessary.

Requirements

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.

Skills Needed:

• 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.
• 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.

Education and Experience

Minimum -

Bachelor's degree

Strong industrial experience as a Process Engineer

7-10 years of practical manufacturing and engineering experience in designing and improving manufacturing processes

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 Toyota Production System (TPS), Lean Manufacturing, and Six Sigma.

Supervise the daily activities of maintenance department, including 3-5 maintenance technicians and custodial staff.

Travel is required.