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Lean Manufacturing Engineer

Grote
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Job Role/Summary:

Develop concepts and cost estimates for new equipment, processes, and workstations for proposed new products.  As a member of multiple new product introduction teams, develop Manufacturing Plan, Floor Layout, Process Flow, PFMEA, and Gage Plan for new processes and work cells. Use Creo CAD package to design new equipment, workstations, and fixtures for new and existing product.  Provide fixture/workstation component and assembly drawings and operation sequence order to internal and external resources and oversee the construction and programming of new workstations and work cells. Develop setup instructions, operator work instructions, machine manuals, critical spare parts list, Master Samples for verification of Poka Yokes, and Preventive Maintenance tasks for new work cells.

 

Responsible for manufacturing process troubleshooting and technical support. Responsible for leading analysis of root cause/corrective action for Quality Concerns related to manufacturing equipment and processes. Responsible for supporting Engineering Change Requests.

 

Support or lead cost reduction efforts including I.D.E.A.S. program, Grote DMS, and Lean Kaizen activities. 

 

Assist in maintaining and updating routings, labor standards, work instructions, and work cell layouts.

 

 

Job Responsibilities:

Essential & Secondary Functions:

 

Safety:

  • Responsible to follow all safety procedures and practices.

 

Quality:

  • Ensures and maintains the quality guidelines, procedures, and standards are consistently followed throughout the manufacturing operation.

 

Responsibility & Customer-Focused:

  • Provides labor estimations for new product and engineering changes.
  • Determines fixturing and testing equipment needs for new product and engineering changes.
  • Plans work center layout.
  • Develops flow chart for new products.
  • Supports manufacturing floor.
  • Designs tooling and machines.
  • Estimates tooling costs for new programs.
  • Provides assembly process troubleshooting.
  • Develops corrective actions for any assigned C.A.R.
  • Initiates and completes assembly sample runs for P.S.W. submittal.
  • Develops setup and operator instructions.
  • Direct Tool and Die Maker Specialist, Tool Maker A in construction of equipment, gages, fixtures and work cells.
  • Provides die cost estimates for new products.
  • Justifies cost reduction projects.
  • Submits sample run parts to layout for dimensional inspection.
  • Communicates with Project Manager progress of tooling, fixturing, test equipment, and assembly equipment.
  • Develops process flow, PFMEA, and assist in development of DFMEA, gage plan and control plan.
  • Provides capital budget requirements.
  • Investigates customer complaints and other problems in area of responsibility on the production floor.
  • Purchases equipment and assures compliance with current OSHA and safety standards.
  • Investigates new and improved equipment for use at Grote.
  • Visits customer assembly plants as needed to develop action plans on complaints.
  • Maintains ECN’s, and develops routings, cell layouts and work instructions as appropriate. Maintains production documentation including routings, operator instructions, and similar.
  • Implements Engineering Change Orders (ECO) within the Division.
  • Participates in product and process feasibility and quote development of new products. Researches, recommends, and prepares AR’s for Division equipment.
  • Performs time studies.
  • Drives continuous improvement in processes and methods.
  • Develops assembly equipment, fixturing, and gages as appropriate.
  • Visits vendors for initial sample of new equipment and tooling to review progress and timing.
  • Develops Preventive Maintenance requirements and spare parts list for equipment

 

Integrity:

  • Meets all deadlines set by project timelines prepared by Project Lead.
  • Completes special projects with intent of achieving divisional plan and goal.

 

Other Functions:

  • Required to follow any other instructions and to perform any other duties as requested by supervisor/manager.

 

Competencies:

 

  • Safety Awareness
  • Quality Driven
  • Respectful
  • Honesty
  • Customer Driven
  • Family Oriented
  • Responsible
  • Innovative
  • Responsible Corporate Citizen
  • Team Player
  • Positive Attitude
  • Detail Oriented
  • Effective Communication
  • Results Oriented
  • Process Improvement
  • Cooperation with Others
  • Strategic Thinking
  • Problem Solving
  • Analytical

 

Education, Experience, Training, Certifications and Licenses: 

Degree or equivalent experience:

  • Bachelor’s degree in mechanical engineering or related field.

 

Years of experience:

  • Minimum 3 to 5 years of industry experience preferred.
  • Willing to consider entry-level candidates.

Training in:

  • As required. 

Licenses in:

  • As required.

Certifications in:

  • As required.

Other requirements:

  • Must successfully pass any pre-screening test(s).

 

Knowledge, Skills, and Abilities:

Knowledge in:

  • Considerable knowledge in Engineering Principles

 

Skills in:

  • Attention to detail
  • Multi-tasking
  • Organization
  • Excellent written and oral communication

 

Demonstrated ability to:

  • Ability to interact with all levels of employees
  • Work at a highly motivated level with a sense of urgency and dedication to accomplishing tasks
  • Ability to type on computer keyboard for extended periods of time
  • Adapt to frequent changes in work environment & prioritization.
  • Work with general or minimal supervision
  • Leverage existing and potential training

 

Experience with:

  • Conflict resolution
  • Problem solving
  • Prioritizing and executing multiple projects

Other:

  • Must be proficient in use of a personal computer, laptops, tablets, smartphone, printer, calculator, copier, and fax machine.
  • Must be proficient with Microsoft Office applications and data entry.
  • Extensive Excel experience and MS Project is a plus

 

 

Travel: 

  • Less than 10%.

 

Work Environment:

  • Manufacturing and/or professional environment.
  • Environment can be hot or cold depending on outside temperatures.
  • Requires flexibility to schedule and work hours.

 

Physical and Mental Requirements:

Physical:

  • Climbing Stairs: Ascending or descending stairs to gain access to a building or to move from one floor to another. 
  • Light Carrying: Physically transporting general office items/materials from one location to another. 
  • Fingering: Typing for extending periods of time, or otherwise working primarily with fingers rather than with the whole hand or arm.
  • Sitting: Particularly for sustained periods of time 
  • Visual Requirement: Able to see and read PC screens; detect color coding, read fine print, and/or normal type size print.
  • Bending and Stooping: Bending body downward and forward by bending spine at the waist. 

 

Mental:

  • Ability to understand, remember, and apply oral and/or written instructions or other information. 
  • Ability to organize thoughts and ideas into understandable terminology. 
  • Ability to compose letters, outlines, memoranda, and basic reports and/or to orally communicate technical information.
  • Ability to communicate with individuals utilizing a telephone; requires ability to hear and speak effectively on phone.
  • Ability to express or exchange ideas by means of the spoken word, communicating orally with others accurately.

Grote Industries will provide reasonable accommodations, if needed, to qualified individuals with disabilities to assist employees in performing the essential functions of their jobs, unless such an accommodation would create an undue hardship on Grote Industries.