GE Appliances, a Haier company Process Improvement Engineer in Decatur, Alabama

Job Location

USA, Decatur, AL

Job Posting Title

Process Improvement Engineer

The Challenge

Manages equipment and process effectiveness within a production area. Provides technical support, troubleshoots process issues and drives operational improvements, through effective problem solving and corrective action implementation, to continuously improve safety, quality, delivery, cost & morale.

What you will Do

EQUIPMENT:

  • Own all equipment and tooling in the production area, from Advanced Mfg Engineer (AME) sign-off and forward.

  • Serve as the primary troubleshooting resource for the process in the plant. Consult with maintenance staff on equipment repair.

  • Monitor and work to improve Overall Equipment Efficiency (OEE) in the area.

  • Recommend equipment and tooling for existing process; consult and sign-off on new purchases when applicable.

  • Audit Preventative Maintenance plans to ensure compliance and maximize equipment uptime.

  • Consult with Maintenance Business Leader on the maintenance action item list and/or priorities for the area.

  • Monitor and ensure the calibration of all equipment.

  • Manage and maintain special tools for the area (i.e. ensure spare tools are in crib, tool drawings in place, facilities hand-off).

  • Provide feedback on equipment specifications (Gray Book content) based upon best practices and lessons learned.

PROCESS CONTROL :

  • Ensure Manufacturing Control Plan (MCP) is executed and adhered to within production area.

  • Maintain process-level standards/procedures.

  • Adjust, monitor and document technical processes (stamping, molding, foaming, etc.), including deviations, MCI, MCP via BCR process.

  • Work cross-functionally with multiple stakeholders to quickly address and solve production line issues (i.e. Team Leader, BL, QSE, QIE).

  • Partner with Quality and Operations teams to improve OEE, Scrap, Yield and Service Call Rate (SCR) metrics. Root cause problems to determine what is causing failures and implement appropriate countermeasures.

  • Monitor process, data & reports on a daily basis and drive the resolution or escalation for any defect.

  • Act as a resource to Team Leaders in the creation of Standard work.

  • Support Job instruction method by reviewing and verifying Job Instruction forms.

CONTINUOUS IMPROVEMENT:

  • Engage in and lead problem-solving for production area. Lead root cause identification of problems, implement appropriate countermeasures, and share across as best practice (yokoten).

  • Live, promote and teach the Appliance Performance System philosophy and lead continuous improvement.

  • Partner with Plant Operations personnel to promote and support a team that reacts aggressively to factory inefficiencies.

  • Continuously identify and work to reduce waste in the area.

  • Work cross-functionally with Team Leaders, Kaizen Promotion Officers, Business Leaders and Lean resources on short term and long term improvement initiatives.

  • Implement related countermeasures on manufacturing line(s) (kaizen activities).

  • Implement Poka-Yoke work methods, and develop workstation aids to assist in operator job performance.

  • Support the Team and Business Leaders in the planning and execution of work area rebalancing utilizing Yamazumi charts.

  • Assist Business Leaders to ensure 5S tools are in place for the area (i.e. shadow boards)

SAFETY:

  • Support Business Leader by identifying and implementing safety-related corrective actions and improvements for the area.

  • Assist with action item completion for the area's safety action item list, including corrective actions from near misses, accident reports & ergo assessments.

NPI LAUNCHES:

  • Coordinate with AME on equipment purchases & qualification.

  • Provide the "voice of the plant", giving feedback on lessons learned and plant preferences.

  • Interact with Design Engineers/Technology organization on model changes for manufacturing line set up.

  • Review product prototypes and concepts for manufacturability.

  • Provide feedback to the NPI team on capacity, impact on operator and process stability/sustainability.

  • Participate in product test runoffs.

  • Interface with vendors and OEM suppliers, along with Facilities Engineer, to learn maintenance requirements and equipment troubleshooting. Distribute information and knowledge.

  • Update manufacturing control documents, floor & workstation layouts. Work with Team Leaders on Standard Work and Job Instruction creation.

What you need to Succeed

Position Requirement

  • Demonstrated experience in troubleshooting high volume manufacturing equipment.

  • Proven ability to influence and drive change.

  • Experience in high volume manufacturing environment.

  • Experience in material flow.

  • Solid verbal/written communication skills coupled with strong interpersonal skills.

  • Advanced computer skills - high proficiency in Microsoft products (especially Excel) and ability to grasp new systems quickly.

  • Strong project management and analytical/problem solving skills with demonstrated ability to scope and analyze cross-functional problems to generate/implement solutions.

  • Must have experience applying time studies and/or standard work.

  • Ability to adapt to and juggle changing and competing priorities.

  • Early and/or late hours often required to work around the manufacturing schedule/ timing.

  • Ability to work collaboratively in a cross-functional team environment with both hourly and salary personnel to meet the needs of operators, the program and the business.

  • High initiative, self-starter, proactive, dedicated, results oriented, a team player.

Minimum Qualifications:

  • Bachelor’s Degree in Engineering or technical field, or equivalent education & experience.

  • Demonstrated experience in troubleshooting high volume manufacturing equipment.

Preferred Qualifications:

  • SCDP Preferred (OMLP)

  • 3 years’ experience in Manufacturing Engineering/Operations/Quality support roles or equivalent military experience.

  • 3 years or more leadership experience in manufacturing operations.

  • Knowledge of Appliances manufacturing processes.

  • Experience in Controls, PMs, mechanical, hydraulic, pneumatics and welding techniques- especially laser welding.

  • Hardware experience should encompass microcontrollers, PC card I/O, PLC, distributed I/O, wireless networking, and a large diversity of instrumentation.

  • Experience and training in lean manufacturing practices.

  • Six Sigma Black Belt certification.

  • Quality Leadership experience.

  • Program Management skills.

Working Conditions:

  • Working conditions are normal for both an office and manufacturing environment.

  • Work may involve lifting of materials and product up to 25 pounds.

  • Working in the manufacturing environment requires the use of safety equipment to include but not limited to: safety glasses, hearing protection, gloves, work shoes/boots.

  • Work may require occasional weekend and/or evening work.

  • Travel may be required for domestic and/or international travel to other sites/plants, etc.

GE Appliances is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.