Sr.Production Process Engineer

Lear, a global automotive technology leader in Seating and E-Systems, enables superior in-vehicle experiences for consumers around the world. Our diverse team of talented employees in 38 countries is driven by a commitment to innovation, operational excellence, and sustainability. Lear is Making every drive better™ by providing the technology for safer, smarter, and more comfortable journeys. Lear, headquartered in Southfield, Michigan, serves every major automaker in the world and ranks #179 on the Fortune 500. Further information about Lear is available at lear.com or follow us on Twitter @LearCorporation.

Eagle Ottawa (EO)is the world's largest supplier of premium automotive leather. Since 1865, we've consistently demonstrated our passion for leather making – in skilled craftsmanship, unparalleled artistry and a focus on innovation. Eagle Ottawa Thailand (EOT) Finishing & Cutting plant construction has been newly completed in 2011, which is located in Rayong. There’re more than 600 employees in this plant.

The Role
Key responsibilities include the following:

1.Cutting Process capability and Improvement.
2. New Cutting equipment or Cutting process development in Thailand
3. Cost control within budget
4. Production layout with lean conception
5. Quotation provide on time and Accurately

Functional Job Activities

Activity 1: Product and Process Development & Validation for new programs

Goal Ensure to meet customer’s timing / quality requirement with validated manufacturing capability.

1.   Work with Commercial to receive and control customer drawings and math data

2.   Review customer drawings and math data and create engineering BOM and Process.

3.   Order tool and validate tool according APQP timeline.

4.   Conduct pattern layout study to support product and process validation and quotation (for leather utilization study)

5.   Provide cutting secondary process study including cost, lead time and new process / equipment feasibility study timely to engineering director.

6.   Arrange functional samples (paperwork) building to support internal/customer validation.

7.   Work with Quality and production to review PFMEA and Control Plan.

8.   Define and optimize packaging design.

Activity 2: Lead process improvement to get an optimized cutting production (including cutting and its secondary operation processes) for mass production programs.

Goal Ensure process capability to meet customer expectation and reduce production cost 

1.   Define and maintain Bill of Material and routine.

2.   Construct and optimize cutting process flow and production line layout

3.   Work with IE to calculate production cycle time to define capital investment and direct labor / indirect labor to support commercial team quotation.

4.   Design and source production tooling, jig and fixture to support mass production need.

5.   Work with quotation manager and material dept to define and improve package design

6.   Ensure to work with lean team to implement lean production processes, e.g Standardized work.

7.   Lead process optimization in term of optimal parameter setting, process capability study, FMEA, DOE, yield analysis and improvement (process yield) and cycle time reduction.

8.   Flawlessly execute engineering change process to make sure production compliance to updated process

9.   Overall ensure production follow process definition and control plan.

10.Take process yield ownership: set up yield database and track / analyze at least weekly base, resolve top 3 yield loss as continuous improvement initiative.

11.Develop and train operator to follow best nesting methodology to get optimal leather utilization.

12. Design tooling, jig and fixture, production table for finishing production, purchase and  ensure required tooling are available for production

Activity 3: Establish and update technical documentation

Goal Documentation control compliance of ISO9000 / IATF16949 system

1.Create and update engineering bill of material, cutting routine

2. Create and update process flow chart

3. Work with IE to create and update production layout

4. Other engineering documents  control, e.g. PFMEA, Working Instruction, Flow chart etc.

5. Train and ensure production follow the updated engineering documentation / specification..

Activity 4: Cutting die construction and maintenance

Goal Ensure cutting die quality match production requirement

1.Construct optimized cutting die for new program.

2. Manage and ensure right quantity and quality of cutting dies for mass production programs, ensure cutting die available and validated for forecasted production ramp-up.

3. Manage in-house and outsourced cutting die maintenance activities, ensure maintenance process control meet EO standard requirement and IATF16949

4. Upgrade cutting die construction, optimize cutting press control and cutting board selection to sustain long life usage of cutting die and cutting board and less die maintenance cost.

Activity 5: Various Plant Support

Goal Ensure product and technical problem be solved timely

1.  Lead process problem solving activities using 8 D / PSR format.

2.  Execute new equipment acceptance test and develop acceptance criteria for new model of equipment.

3.  Apply Best practice sharing from peer EO plants to proliferate to EOT facility.

4.  Launch and APQP support: study and develop new process or equipment to match new requirement from customer.

5.  Support plant lean and 6 sigma project and initiate continuous improvement project.

6.  Provide necessary document and information and work with IE to get capital expenditure approved.

7.  Any ad hoc support requirement from plant regarding Cutting process perspective.

Activity 6: Safety and on site contractor management

Goal Manage on site engineering activity is conducted in a safe and secure way through prior training and education.

1.     Ensure to apply safety requirement and Ergonomic consideration to accept a new process or new equipment.

2.     Responsible for all the Level 3 safety training to all the operators.

3.     Ensures all the on site construction or machine installation related activities are in line with safety and environment as well as secure requirement through training and education to the workers.

4.    Makes sure all the workers have insured for themselves and declared their responsibilities and liabilities in written form.

Activity 7: Goal

1)    Training

b.     Analyzes self knowledge and skills, propose self-annual training needs based on the Performance Appraisal Result.

c.     Is willing to share knowledge and experience with other people to help build a learning organization.

2)    Performance Management 

Follows all procedures associated with the EOT Performance Management Program, manages own performance to ensure on going improvement.       

3)    Career Development

Is encouraged to actively develop own career by obtaining the most up to date knowledge and skills.  

4)    Employee Relations

Maintains amiable, respectful working relationships with co-workers both inside and outside the Department.

Qualifications

1.University degree with Mechanical, Industrial Engineering   or related background;

2.Good written English. Be able to use Auto CAD, Solid Work .

3.Over 5 year’s relative experience. Multinational manufactory experience is preferred

4.Familiar with mechanical manufacturing process.

5.Prefer on leather industry experienced, good eyesight or Seating Automotive Industry .

6.Must be a team player with good communication and interpersonal skills

7.Knowledge or Skilled implement Innovation experienced.

Advantages Of Working At Lear

Lear Corporation is an Equal Opportunity Employer, committed to a diverse workplace. Applicants must submit their resume for consideration using our applicant tracking system. Due to the high volume of applications received, only candidates selected for interviews will be contacted. Unsolicited resumes from search firms or employment agencies, or similar, will not be paid a fee and will become the property of Lear Corporation