Description
We are seeking a Process Engineer (Gear Machining) to join our team at Ford Motor Company in Sterling Heights, MI. The successful candidate will have a deep understanding of specific manufacturing disciplines, particularly gear machining (blanking, hobbing, turning and milling).
The role involves evaluating the ergonomics of various jobs to ensure operator safety and leading 'Visual Factory' management to make production status and issues transparent to all team members. The ideal candidate will balance hands-on technical support with administrative oversight of process documentation to ensure manufacturing processes are stable, efficient, and capable of meeting rigorous automotive production standards.
Responsibilities:
- Support Manufacturing Process Engineering activity
- Drive continuous improvement in safety, quality and productivity
- Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products
- Develop action plans to investigate and prioritize quality concerns and verify corrective actions on internal processes and supplier processes
- Lead and conduct process audits to ensure process discipline is consistent with guidelines
- Conduct job ergonomic evaluations and deliver corrective actions as required
- Analyze vehicle inventory root causes and engage in mapping and corrective actions to reduce vehicle inventory
- Create process and instruction sheets supporting quality methods and processes
- Deliver capable processes and tools for Trim and Chassis Assembly operations
- Lead variability reduction and lean manufacturing initiatives and best practices
- Ensure compliance to Plant, Corporate, Governmental and Environmental standards
- Back up ISO 14001 compliance and support internal ISO auditing and compliance as required
- Support continuous improvement in safety, quality and productivity
- Identify throughput constraints and drive root cause improvements
Qualifications:
- High school diploma or GED
- 1+ year of Process Engineering experience (can include co-op/internships)
- 1+ years of experience working in a manufacturing environment (internship and coop experience will be considered)
- 1+ years of experience with gear machining, blanking, hobbing, milling and auxiliary processes
- Ability to work overnight off-shift on 4 person-crew.
Preferred qualifications:
- Bachelor’s Degree in Engineering preferred
- Effective oral and written communication skills
- 2 or more years in the automotive industry
- Lean Manufacturing and Six Sigma experience
- 8D and 5Why corrective action and problem solving skills
- Solid understanding of Lean Tools – 5S, Kanban, Poka-yoke, and Value Stream Mapping
- Familiarity with DMAIC and DMADV (DFSS) Project Methodology experience
- Knowledge of TQM and Kaizen Methods, FMEA, PPAP, and DOEs experience
- Validated experience with Visual Factory Management
Benefits:
- Immediate medical, dental, and prescription drug coverage
- Flexible family care, parental leave, new parent ramp-up programs, subsidized back-up childcare and more
- Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
- Vehicle discount program for employees and family members, and management leases
- Tuition assistance
- Established and active employee resource groups
- Paid time off for individual and team community service
- A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
- Paid time off and the option to purchase additional vacation time.