Role Summary: Manufacturability review of new products, feasibility study of new requirements from customers, process trouble shooting, continuous improvements for safety, quality and productivity, introduce new machines or modify current machines to meet capacity increasing or higher performance requirements
Main Responsibilities / Tasks: 1. Involve in new product design review from manufacturability point of view and create a standard review list and dynamically maintain it according to the lessons learned from past projects; 2. Technically support PMs and technical team to do feasibility study of new production process related requirements from customers; 3. Learn and understand the machine a. Find the manuals, if some manual cannot be find keep in touch with Italian manufacturing engineer team or supplier to find it and save on the server. b. Read and memorize the manuals. c. Update the manual according the improvement done by time. d. Understand daily requirements for maintenance, quality settings etc. e. Be able to take apart machine and put back together. Understand schematics and machine characteristics. f. Be able to clean the machine and understand preventative maintenance requirements. g. Understand what each part of the machine does, how it does it and why it does it. h. If one parameter is changed on the machine what will be the impact. 4. Analyze the data of last day of production, if efficiency is lower than target investigated about reason and problem. Starting from breakdown, scrap and rework rate analyze the problem, find the root cause and define and implement the corrective action. Solve the problem instead of manage the problem. 5. List any gaps (problems) between current state and targets. For each problem find root cause and define and implement the corrective action. 6. Study the process and the machines to understand the root cause of the problem. a. Get hands dirty, run the machine, do the physical setup, do the adjust process. b. Become the machine. 7. Develop counter measures to solve the problem. a. Be able to sketch ideas on paper for changes to machine, fixturing, programming etc. 8. Create action plan how to solve the problem and be responsible to complete it. a. If necessary fix the problem by yourself. b. Design a fixture or solution and get supplier to build it. c. Be able to measure the supplier solution to see if it meets the drawing and tolerances. 9. Verify cycle time of the machine and work to reduce it even if it is operating at the designed mfg. speed. a. Define the action to be taken and be responsible to complete it or see that it gets completed. 10. Define for each machine the possible improvement, create project card and follow till the implementation and validation. 11. When receive the project card, define the actions to be done, how long it should take and the deadline. 12. Follow up project and perform a final inspection. a. Should never receive a layout with common sense mistakes i.e. conveyor block the door. 13. If quality of supplier job is low is our fault, not supplier fault. We are fully responsible for supplier, in term of timing, quality and safety. 14. Create purchase request in SAP, follow up approval until purchase order is created and sent to supplier. When material is arrived and if is according to our specification, write to warehouse to make SAP reception. 15. For the project that request an investment and need be capitalized, apply for a PAR and prepare supporting material, evaluate cost, saving and benefit. Work with finance to calculate payback and ROI. Follow up PAR approval, and when done create PR and PO on SAP, follow up approval and keep track of the cost compare to the budget. 16. Need Lean solutions a. Everything on wheels b. Easy to move c. Quick disconnects d. Flexible e. Mixed model capable f. Zero setup time 17. Create a weekly report with the activities on going (5 Up report). a. If need help you ask. Do not wait for someone to ask you. 18. Follow up machine installation until machine is running at 90% efficiency for 24 hours. a. Be able to manage a new installation project schedule, considering safety as a priority. Work with Italian manufacturing engineering team to assure machine construction on time and according to ITT Wuxi specification. b. Be able to follow up on the schedule to make sure dates are hit c. Be able to expedite the supplier and go as high as necessary in the supplier organization to get good answers and understand the status of the new machine. d. Make sure all ITT support functions are in place to support the project schedule and define the validation process (ESH, quality, production, maintenance) e. In case no activities to be done or they are going to be late, go to your supervisor to ask for instruction. Problems are welcomes, but you are responsible to solve. Don’t think you will get the solution from your supervisor, he will just support you. 19. Create standard work instruction. a. Know what the process does b. Know how the process does it c. Know why it does it d. Need proper sequence of detailed steps, Key points, reasons for key points and cycle times (AFTER non value added activities are removed). e. Standard work is also necessary for machines and robots etc. f. How to make sure operator runs the machine correctly i.e. not just the workstation but make sure the last robot on finishing line never stops. 20. Define the list of spare part necessary for each new machine and provide to spare part warehouse and maintenance. a. Look for predictive maintenance opportunities 21. Define layout for machine and facility. a. Flexible layout b. Machines can be easily moved c. Flexible utilities d. Focus on one piece flow – zero wip 22. Never pass on a bad part from one step to the next is the overall goal. 23. Comply with ESH policy and procedure, implement ESH responsibilities，carry out ESH activities, keep all operations in line with ESH requirements and deliver ESH performance. 24. Other jobs assigned from the supervisor.
Qualifications/Requirements: 1. Bachelor degree or above, major in mechanical design or manufacturing engineering or automation related; 2. Be familiar with the application knowledge of the normal components of automatic manufacturing and assembly lines such as the different kinds of sensors, actuators, robots, industrial cameras and so on; 3. Experience in mechanical design or electrical design of non-standard machines is highly preferred and even necessary; 4. Ability to operate standard office business machines. Requires MS Office skills, Ability to use AutoCAD software or similar； 5. Excellent organizational skills; ability to effectively determine priorities and meets deadlines; 6. Orientation in machine documentation; 7. Experience with hydraulic and compressed-air systems; knowledge of compressed air system, cooling water, suction, vacuum, electric power distribution 8. Flexibility (VERY often need to overtime work). 1. Passion and ITT DNA. Passion is all for us, we work hard because we enjoy, we appreciate and promote overtime, if a job can be done today don’t wait tomorrow. Work hard to meet your goal and company goal; 2. No excuses; 3. Abandon fixed ideas. Reject current state of things; 4. Instead of explain what cannot be done, reflect about how it can be done; 5. Go for simple solution; 6. Correct mistakes right away; 7. Find idea in the difficulty, Look problem as opportunity to improve; 8. There is no end to improvement; 9. If you have free time, go around and find new improvement opportunity by yourself; 10. Don’t wait always your supervisor approval or input, you are accountable for your job; 11. If you have some blocking point and you must get supervisor approval, push him to have. If after 2 times he will not answer you, go to next level manager; 12. Nothing is too complicated or complex; 13. Everything is possible; 14. Drive for perfection; 15. Zero defects on machine; 16. Supplier need work according to our request and specification, not according their will; 17. Look for 100% FTT ; a) Be able to figure out how to get automated inspection b) Be able to design or find supplier to design Poka yoke solutions 18. Be accountable; a) Meet your commitment dates b) Should never have to follow up with you. If you can’t meet a date, should let us know ahead of time and have work around recovery plan c) After you try your best, and still cannot achieve the results, ask to supervisor or other another colleague for help d) If machine has problem and maintenance is busy, we fix the problem together, we need work as a team e) If machine has problem and maintenance has problem to fix, contact equipment supplier or Italian expert to get help. If you don’t get help the *** time, push them. If after 2 trials no feedback look for your supervisor. 19. Problem solving skills; a) A3 b) PDCA 20. Positive attitude; a) Look at all challenges as opportunities b) Don’t be afraid to fail. c) Every mistake need be recorder to create a lesson learn for all the team d) Take risks e) Wild ideas f) Anything is always possible 21. Ask for feedback on how you can be better and on what you are doing well. Be able to take the feedback and say thank you; 22. Feel free to push back if you disagree and think you have a better idea but in the end it is up to the boss to decide. Then you need to be a good follower; 23. Team work – need to be able to work as a team and have good interpersonal skills with others; 24. Always ask why something is done. Improvement process is always look at each step to see if we can eliminate it, rearrange it, simplify it or combine it with something else.
