Power Busbar Mgr R&D/PRODUCT DVL ENGINEERING
TE Connectivity
AssemblyCloud
Engineering Specialist, Process
Ford Motor Company
full-time
Posted on:
Origin: • 🇿🇦 South Africa
Visit company websiteJob Level
Mid-LevelSenior
Tech Stack
Assembly
About the role
- Lead Manufacturing Process Engineering for Final Assembly (Trim/Chassis), driving 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 and supplier processes.
- Conduct process audits to ensure process discipline and adherence to Vehicle Operations guidelines.
- Conduct job ergonomic evaluations and deliver corrective actions as required.
- Analyse vehicle inventory root causes; map and implement corrective actions to reduce vehicle inventory.
- Deliver capable processes and tools for Trim and Chassis Assembly operations; maintain fixture/jig integrity and backups.
- Lead resolution of assembly-related concerns; lead variability reduction and lean manufacturing initiatives.
- Identify throughput constraints and drive root cause improvements; identify and close all FRC issues within Chassis/Trim.
- Support MTC changes, efficiency activities, and warranty investigations within Chassis/Trim areas.
- Program launch management: confirm layouts, material/pedestrian flow, ensure parts fit and layout standards, and complete zoning prior to GDPS milestones.
- Support and lead build events (Slow Build, TT, PP, MP1, FCPA, FER), participate in "war room" meetings, capture/bin build issues, and ensure robust 8D/5D/4D closure actions.
- Conduct content change analysis with launch team and ensure countermeasures and training are implemented.
- Lead Workstation Readiness Assessment (WSR) prior to builds and ensure Part sign-off for Non-PPAP parts.
- Ensure Plant QOS processes are active: gauging strategy, equipment capability, traceability, DCP, OIS/WES, QCM, error-proofing, inspection, and calibration.
- Review and implement High Hurts Matrix items; support Whiteboard meetings to ensure ICA/PCA within 24 hours.
- Incorporate teardown and test result corrective actions into manufacturing and EOL testing processes.
- Ensure Risk Assessments, Pre-Task Assessments, PROTAG sign-off, JSA completion, signage and chemical hazard controls, BBQ/backups, ISO 14001 compliance, and safe equipment disposal.
- Lead cost initiatives: implement one cost-saving project per year and one Kaizen project per month.
- Collaborate extensively with Manufacturing Leadership, Quality, Production, Maintenance, LPWR, Product Development, VME, suppliers, and cross-functional teams.
Requirements
- Bachelor's degree in Mechanical / Electrical or Industrial engineering.
- 5+ yrs of related experience.
- A certified green belt has an advantage.
- Ariba access and use has advantage.
- Successful candidate must be able to demonstrate leadership in ONE FORD (leadership) behaviors combined with outstanding interpersonal, teambuilding, and communication skills.
- Lean Manufacturing and Six Sigma experience.
- 8D and 5Why corrective action and problem-solving skills.
- Lean Tools – 5S, Kanban, Poka-yoke, and Value Stream Mapping.
- DMAIC and DMADV (Design for Six Sigma) Project Methodology experience.
- TQM (Total Quality Management) and Kaizen Methods.
- FMEA (Failure Mode and Effects Analysis), PPAP, and DOEs (Design of Experiments) experience.
- Ergonomic analysis knowledge and experience.
- GSPAS/APT; CLL/Auto CAD; Wow Falcon / WERS; Illustration, MOVIS, AIS.
- Knowledge of Plant Layout, Material Flow Diagram, Pedestrian Flow standards (e.g., FAS08-079).
- Risk Assessment methodologies (e.g., FAS08-036).
- PROTAG procedures and sign-off processes.
- Chemical Hazard Communication Standard (FAS08-252) and Toxicology (TOX) number management.
- Job Safety Analysis (JSA).
- Quality Operating System (QOS) processes, including Gauging, Traceability (QLSCM), DCP, OIS/WES, QCM, Error Proofing systems, and Inspection Processes.
- Experience with Production FIS/IIOT systems.
- Build event management (Slow Build, TT, PP, MP1, FCPA, FER) and related procedures.
- Workstation Readiness Assessment (WSR).
- LPWR processes and eFPS.
- Effective oral and written communication skills.
- Strong leadership capabilities (ONE FORD behaviors) and outstanding interpersonal, teambuilding, and communication skills.
- Problem-solving and analytical thinking; ability to drive continuous improvement and lean manufacturing initiatives.
- Strong organizational and planning skills; results-oriented with a focus on meeting KPIs.
