Senior Manufacturing Engineer

Manufacturing Process Improvement Manager

Develops and implements best practices related to lean, cost efficient, and state-of-the-art manufacturing processes. Leads projects in the manufacturing environment from the concept phase through production implementation. Exhibits skills for being a strong, team-oriented, employee able to prioritize and perform multiple tasks as required. Identifies and develops solutions for improvements in safety, quality, productivity, and cost by utilizing strong problem-solving skills. Develops and implements manufacturing best practices for Nortek Air Solutions Oklahoma Facilities.

Primary Job Functions:

• Develop and implement best practices for manufacturing HVAC coils, sheet metal fabrication, welding, and assembly processes.
• Collaborate with Design Engineering and support departments to successfully introduce new products and influence the design of products for ease of manufacturing.
• Manage projects consisting of relocating existing equipment in a cross-functional team environment.
• Develop optimized workstation layouts to support lean assembly processes, as well as improved ergonomics for production operations.
• Support development of lean logistics flow and material presentation throughout the facility.
• Foster continuous improvement process with leading principles of Safety, Quality, Productivity, and Cost.
• Generate capital equipment requests, along with required support documentation.
• Drive manufacturing cost reduction initiatives to meet production cost targets.
• Develop manufacturing routings and perform time studies for production management and standard cost efforts.
• Design required weld and assembly fixtures to facilitate repeatability and ease of assembly, by utilizing AutoCAD design software.
• Select most efficient and cost effective tools for assembly processes.
• Support operations management to resolve production and quality problems, via root cause analysis.
• Generate project status reports and review with Director of Operations.
• Develop production capacity, staffing models, and standard production playbooks.
• Develop operator standard work and operator work instructions.
• Conduct Continuous Improvement workshops to educate associates on the fundamentals of Lean manufacturing.
• Improve productivity and promote Lean culture throughout the organization.
• Conduct training and understanding of the Nortek Production Systems.
• Responsible for the roll-out of the Nortek Production System Level 1-4 meeting/communication process.
• Work closely with the Director of Operations in planning and execution of Oklahoma business strategy.
• Monitor and informs the Director of Operations on issues related to production efficiency.
• Improve safety issues related to ergonomic and standard work practices.
• Increase equipment availability by implementing Total Productive Maintenance program.
• Optimize the facility layout, line balancing, and process flow to improve production efficiency.
• Implement workplace organization (5S) and visual management processes to streamline operations.
• Set up Kanban pull systems for material flow within the production facilities.
• Analyze and improve flow, presentation, and handling of material between processes.
• Perform Value Stream Mapping of processes to identify and eliminate non-value add activities.
• Promote one-piece flow and standardized work within Oklahoma facilities.
• Establish process flows, cell layout, staffing planning, material flow and best practices for new and existing processes.
• Read and understand fabrication and assembly drawings and can synthesize to others.
• Exhibit a solid understanding of dimensional tolerances and their interactions with other components.
• Act as a subject matter expert on the required manufacturing steps to produce completed units. (fabrication to assembly)
• Compile various training materials and effectively teach others a given process or technique.
• Assist in the coordination of new product introductions, confirming that new tooling and production documentation are in place.

Knowledge, Skills, and Abilities:

• Experience in planning and coordinating new program launch activities
• Experience in coordinating special projects, purchase, and justification of capital equipment.
• Experience in creating process flows and work standards.
• Experience in performing manufacturing cost calculations and managing cost reduction projects.
• Hands-on capabilities of prototyping, fabricating metal parts, and testing is also required.

Job Qualifications:

• Bachelor's degree in Mechanical Engineering or related Engineering discipline.
• A minimum 5-year record of successful lean transformation projects in a manufacturing environment is required.
• Strong mathematical, analytical and overall computer skills.
• The ability to work collaboratively within a team environment.
• Must have excellent written and verbal communication skills and strong analytical and problem-solving skills.
• Must be able to read and evaluate mechanical drawings and technical specifications.
• Must be proficient in Microsoft Project, Excel, PowerPoint, Word, AutoCAD drawing software.