SUMMARY: Develop manufacturing process and production methods; provide production support to enable manufacture of high quality engineered products. Work concurrently with Manufacturing/Engineering Development Manager through new product development and cost savings projects. Introduce and maintain state of the art processes and equipment into the workplace by implementing lean manufacturing concept
Support all safety requirements and guidelines including awareness training of shop personnel as needed during daily activities.
Create and enter process routings and operational instruction sheets. Maintain all work center cost standards, labor standards, etc. for cost and labor reporting.
Produce part manufacturing routings and instruction sheets, design manufacture and manage the tooling required to support all phases of production, including, but not limited to paint fixtures, molds, dies, assembly fixtures, test fixtures and production aids. Responsible for tooling rework instructions.
Develop material and information flow chart for both manufacturing processes and business processes; Be instrumental in identifying and reducing non-value added activities; identify the causes of wastes in the processes; Initiate and follow up the corrective action to improve efficiency.
Provide on the job training to implement new and revised processing methods for production personnel
Provide cost savings through process improvements, design refinements and workflow enhancements. Utilize lean manufacturing tool to improve process control; participate the cross functional team to initiate the control plans and implement the controls on shop floor per approved control plans.
Troubleshoot and lead the corrective action to the waste identified at the following processes, but not limited to: rubber molding, met-l-flex, production and machining problems
Maintain documents related to SPC, routings, operational instruction sheets, and production log sheets as required
Provide support to Engineering for ECO/ECN review and implementation of changes into production for the production parts which have been fully transferred Operation.
Provide support to Manufacturing /Engineering Development Manager from design concept through, prototype and production phases on new and redesigned products. Lead the cross functional team for risk management, implement the corrective action to mitigate the identified risks.
Provide support for cost estimates for manufactured component parts being procured from outside vendors and detailed estimates for complete assemblies for new products and parts produced in-house.
Provide cost justifications, for equipment and tooling, including payback and return on investment calculations, to reduce production costs or cycle times. Provide presentation to clearly illustrate the justification for the required investment.
Support MRB by providing dispositions, rework instructions, cause and corrective actions if applicable.
Improve plant layout with regard to flow requirements. Incorporate all facets of process flow and workstation design including utility requirements in the factory layout.
Work with and support production in the implementation and use of SPC, capability studies, etc.
Provide machining, manufacturing and technical support to our suppliers and customers. Provide supplier capability studies. Provide direction and support for machining of new parts and machining problems.
Assist as required with regard to compliance with hazardous materials laws in the areas of reporting, storage and safety.
Provide production support by interfacing with support groups such as the test lab, rubber mixing and Materials and Processes Engineering.
Keep up to date and stay close to Front end technologies, including the new tools, processes and work flow.
KNOWLEDGE, SKILLS, AND ABILITIES REQUIRED:
Education and/or Experience: Engineering degree or equivalent experience in the aviation or aerospace industry. Rubber molding and machine shop environment background required. Extensive lean manufacturing training. Previous teamwork, SPC training required. Proficient in use of computer word processing, spreadsheet and CAD programs.
Ability to initiate the continuous improvement project: establish clear problem statement, project objectives, identify dependencies, set up key metrics, estimate the cost of the project, justify the proposed project with cost efficient project management to ensure the approval from top management.
Language Skills: Ability to read and interpret engineering documents such as drawings, specifications and procedures in English. Must be able to convert engineering data and specifications into shop floor instruction sheets. Ability to communicate effectively with management, staff, co-workers and production personnel. Ability to effectively communicate with vendors, customers and co-workers.
Mathematical Skills: Basic math skills and knowledge of the application of algebra, trigonometry and geometry in the related fields of manufacturing and design engineering. Should possess ability to perform basic rubber design calculations to provide feedback and input to design problems. Ability to perform metric conversions.
Problem Solving: Ability to define problems, collect data, establish facts and draw valid conclusions. Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables. Ability to initiate a basic Design of Experiment (DOE) to validate the potential solution of the problem on hand.
Teamwork and other Skills and Abilities: Ability to participate as a team member, daily or in meetings. Ability to listen actively and respond in group discussion. Willingness to learn other job skills and assist other team members when available. Ability to understand team and business goals. Ability to develop partner/team relationships with vendors.