Process Engineer

Job Summary:

Our client in Sterling Heights, MI is looking for a Process Engineer. This is a Direct Hire position.

What You Will Do:

• Evaluate efficiencies by comparing process standards such as labour hours, machine cycle time to actual production values and report proposed improvement recommendations with timing to Process Engineering Manager.
• Initiate continuous improvement activities for cycle time reduction, direct labour reduction, alternative materials and scrap reduction for products assigned.
• Analyze SPC, FMEA’s, DOE, and process parameters and co-ordinate the necessary improvements to achieve capable processes.
• Improve the quality of the end product by developing and implementing error-proofing methods to prevent the manufacture of defects.
• Notify the General Manager/Process Engineering Manager of incapable processes/products.
• Co-ordinate the implementation of new production equipment until PSO. Initiate the production part approval process as per the APQP requirements.
• Prepare capital justifications for new production equipment, and on-going improvements.
• Investigate and implement production method changes to improve productivity on a continuing basis.
• Act as technical contact for vendors.
• Prepare weekly updates for process capability/performance.
• Actively participate in advanced product quality planning with regards to manufacturing processes i.e. workcell layout, KCC/KPC selection, preventable maintenance schedules.
• Initiate 8D problem solving for control/capability non-conformances. Lead the team in mistake proofing of potential process concerns. Ensure customer notification/authorization, and documentation of all process changes. Initiate Engineering change request for all proposed process changes. File all process related documentation.
• Assist with in-house training programs for assembly personnel to learn new production parts and processes.
• Develop plans/schedules for preventative and predictive maintenance of process equipment.
• Ensure the implementation of new production processes and follow up until process capability is achieved.
• Maintain and update operator instructions, process specifications, process flow charts , process control plans, machine set-up instructions , and process FMEA’s. Develop and review work procedures for all process related functions, i.e. operators, set-up, material handling, and maintenance.
• Arrange with the involvement of Project Engineering sourcing of replacement production tooling, testing equipment, check fixtures and prototypes when required, and follow-up with same.
• Participate in DFA/DFM reviews.
• Responsible for keeping plant personnel informed of quality, process and general product related issues for products assigned through plant information boards.
• Ensure that all processing methods and equipment meet all health and safety requirements. Identify all resins, paints, and raw material to human resources for safety data sheets.
• Any other duty as assigned by the Process Engineering Manager.

Requirements:

• Education: Bachelor’s degree in engineering
• Minimum of two years (2) of manufacturing experience (preferably automotive plastics).
• Good analytical and reasoning abilities.
• Good communication and organizational skills.
• Good computer literacy required.
• Basic mathematics with emphasis on statistical calculations and applications in manufacturing processes.
• Understanding of injection moulding and tooling.
• Understanding of fixturing and assembly machines.
• Understanding of assembly methods.
• Understanding of key Quality & Environmental Management Systems procedures related to job function.
• Complete understanding related forms.

How You Will Be Successful:

• Envision the Future
• Communicate Honestly and Broadly
• Seek Technology and Business “First”
• Embrace Diversity and Take Risks