Process Engineer - Afternoons - ABC Technologies (USA Region)

ABC Technologies is a leading global manufacturer and supplier of custom, highly engineered, technical plastics, and light-weight innovations to the North American light vehicle industry. Serving more than 25 major original equipment manufacturer customers in 7 countries, the Company is Molding The Future and is strategically placed to offer vertically integrated product and process solutions through a skilled workforce of over 11,000 team members. Additional information about the Company can be found at www.abctechnologies.com.

Job Summary:

A Process Engineer in a plant plays a key role in ensuring the efficiency, quality, and safety of manufacturing processes. The purpose of the Process Engineer position is to monitor all processes to ensure customer needs, drawing specifications are being met and to participate in continuous improvement projects as required. It will also ensure all documentation is kept complying with TS16949 standards.

Overall, Process Engineers play a vital role in ensuring the reliability, efficiency, and quality of manufacturing processes, contributing to the overall success and competitiveness of the plant. They combine technical expertise with analytical skills and a commitment to continuous improvement to optimize production operations and deliver high-quality automotive parts to customers.

Job Responsibilities:

Your supervisor may from time to time ask you to perform other related duties not specifically included in this job description. This job's key responsibilities include:

• Process Optimization: Analyzing existing manufacturing processes to identify areas for improvement in efficiency, productivity, and cost-effectiveness. Support Process Technicians as needed. Must troubleshoot and diagnose processing issues. Developing and implementing process improvements, including changes to equipment, materials, layout, or workflow, to optimize manufacturing operations. Conducting time studies, cycle time analysis, and process simulations to identify bottlenecks and inefficiencies in production processes. Conduct process studies and make recommendations to the team that will improve process, machine, and material improvements to enhance manufacturing and maintenance efficiencies.
• Team Collaboration: Work with internal and external teams to ensure the proper tools, fixtures, and additional equipment is in place to meet the required productivity, quality objectives, and cost objectives. Verify with commercial(sales) side that we are doing what our established BOM requirements are. Be a part of tooling, fixtures, gauges, and other equipment development and design. Ensuring that the company will be able to meet productivity requirements, quality objectives, and cost objectives. Communicate with the ABC Technologies team and the customer to ensure both parties are aware of the program status.
• Quality Assurance: Establishing quality control measures and standards to ensure that automotive parts meet specifications and customer requirements. Developing and implementing quality inspection processes, procedures, and tests to detect and prevent defects in manufactured parts. Investigating root causes of quality issues or non-conformances and implementing corrective and preventive actions to address them. Assist in development and implementation APQP documents such as Flow Chart, PFMEA, Standardized Work Instructions, Open Issues List, and other documentation utilizing a team approach. Ensure that all aspects of the Process Engineering Department are in full compliance with the Quality System established and they are being followed.
• Equipment Maintenance and Reliability: Collaborating with maintenance teams to ensure that manufacturing equipment and machinery are properly maintained and optimized for performance. Developing and implementing preventive maintenance programs to minimize downtime and maximize equipment reliability. Analyzing equipment performance data, conducting failure mode and effects analysis (FMEA), and implementing reliability improvement initiatives to enhance equipment uptime and longevity.
• Safety and Regulatory Compliance: Ensuring compliance with safety regulations, environmental standards, and industry best practices in manufacturing operations. Identifying and mitigating safety hazards and ergonomic risks associated with manufacturing processes. Conducting safety audits, inspections, and training programs to promote a culture of safety and continuous improvement.
• Data Analysis and Reporting: Collecting and analyzing data related to manufacturing processes, including production output, quality metrics, downtime, and scrap rates. Generating reports, dashboards, and performance metrics to track process performance, identify trends, and make data-driven decisions for process optimization. Presenting findings and recommendations to management and stakeholders, communicating insights and opportunities for improvement.
• Continuous Improvement: Leading or participating in continuous improvement initiatives such as lean manufacturing, Six Sigma, or Kaizen events to drive efficiency gains and cost savings. Engaging with cross-functional teams to implement best practices, standardize processes, and foster a culture of continuous improvement throughout the organization. Utilize 5S, Lean Manufacturing, and Standard Work to improve manufacturing efficiencies, floor space, and housekeeping.
• Planning: Participate in development of the annual business plan, long range plan, and other action-oriented plans as directed by management.

Job Qualifications:

• Education: Engineering degree or equivalent experience (4-5 years as Process Lead).
• Skills & Experience
  • Technical Skills: 2-4 years of Injection/Blow Molding experience in the automotive industry
  • Understanding of Manufacturing Processes: Knowledge of various manufacturing processes used in automotive part production, including casting, machining, forming, welding, and assembly.
  • CAD/CAM Skills: Proficiency in computer-aided design (CAD) software and computer-aided manufacturing (CAM) software for designing parts, creating tooling/fixtures, and programming CNC machines.
  • Process Optimization: Ability to analyze manufacturing processes, identify inefficiencies or bottlenecks, and develop and implement process improvements to enhance efficiency, productivity, and quality.
  • Quality Control and Assurance: Understanding of quality control methods, statistical process control (SPC), and quality assurance principles to ensure that automotive parts meet specifications and customer requirements.
  • Problem-Solving: Strong problem-solving skills to troubleshoot process issues, identify root causes of defects or non-conformances, and implement corrective and preventive actions.
  • Data Analysis: Proficiency in data analysis tools and techniques to collect, analyze, and interpret data related to manufacturing processes, including production metrics, quality indicators, and performance trends.