Advanced Manufacturing Engineer

Magna International•Troy, MI

About The Position

The Advanced Manufacturing Engineer (AME), Core Drive will lead and take ownership of process planning of powertrain products with a strong focus on cost targets. The AME considers new and innovative manufacturing technologies, as well as best use of installed equipment at the production site. The AME works to develop and implement manufacturing strategies by utilizing product design knowledge, materials, tooling and equipment capabilities, assembly methods, quality control standards and product safety requirements. Creates plans that optimize work force utilization, space requirements, workflow, and product traceability. The AME uses product and customer requirements to create specifications for tooling and equipment. The AME works with vendors to procure, setup and implement into the manufacturing facility along with the Manufacturing Engineers (ME) of the production site. Support Sales, Program Management and Finance during price buildup and the negotiation process.

Requirements

Bachelor of Science in Mechanical Engineering or Manufacturing Engineering strongly preferred
Minimum 8 years of experience required in Automotive Manufacturing or equivalent.
Strong knowledge of state-of-the-art manufacturing technologies for powertrain products.
Knowledgeable in production processes with hands-on manufacturing floor experience
Interaction with Manufacturing and Assembly equipment suppliers
Experience in Electrification Powertrain Products a plus
Experience in Lean Manufacturing Techniques
Working knowledge of DFM, DFA, PFMEA (APIS), QS / ISO / TS / IATF, GD&T, APQP and PPAP
Proficiency in AutoCAD, 3D CAD designs using Inventor and/or Solidworks
Proficiency in Microsoft Office (Word, Excel, PowerPoint), Microsoft Project and Minitab is a plus.
Excellent English written and verbal communication skills, Spanish is a plus
Excellent analytical and problem-solving skills (8D, Shainin or Six Sigma training a plus)
Self-motivated, team player with the ability to lead a team.

Nice To Haves

Experience in Electrification Powertrain Products a plus
Microsoft Project and Minitab is a plus.
Spanish is a plus
8D, Shainin or Six Sigma training a plus

Responsibilities

Lead new quotation activities by providing detailed Cost Estimates to include process flows, capital investments, plant layout, tooling, work holding, gaging, perishable tooling, cycle times, planning and launch costs along with developing master timing charts for achieving manufacturing milestones
Lead Design to Cost, evaluate product specifications of components and assemblies in close coordination with Product Engineering and Purchasing
Develop, refine, and lead manufacturing processes in all manufacturing locations, including plant layout concepts, supply base, logistics, process flows, and workforce utilization to attain maximum efficiency of installed capacity.
Provide Manufacturing Engineering leadership, expertise and support while maintaining a broad knowledge of product design, manufacturing, and assembly processes.
Ensure the consideration of internal process standards and lessons learned, make sure that experiences and lessons learned are communicated back to the organization.
Lead the planning phase for assigned programs and hand over to the manufacturing site for the program launch phase. Consider the required deliverables according to the Global Program Management System (GPMS) and APQP requirements.
Work with the manufacturing sites to establish, select, procure, and install equipment to support the launch of new programs.
Develop the Production Concept during the Quotation and Serial Development Phase: Definition of production site, production technologies (new or innovative), equipment, and “Make or Buy” concept. Manufacturing and Assembly concept (equipment, clamping and tooling concepts, measuring concept, level of automation) and operational quality. Production infrastructure, equipment, and floor layout concept. Execution plan for all Process Engineering Work Packages (Manpower, Resources, Cost and Timing)
Develop the Production Process during the Quotation and Serial Development Phase including: Required process flows for In-House Components and Assembly. Development and verification of new or innovative technologies. Required process and control plans for Off Tool and Off Tool\Off Process. Required process instructions for In-House Components and Assembly
Develop the Production Equipment during the Quotation and Serial Development Phase including: Required equipment for manufacturing of Purchased Finished or In-House Components. Required equipment for Assembly of products. Required equipment for Automation and handling or transfer. Required equipment for Quality Control activities on shop floor
Develop the Production Tooling and Gages during the Quotation and Serial Development Phase: Apply customer Billable Tooling guideline. Reuse of existing Tooling and Gaging located at production site. Required Tooling for manufacturing of Purchased Finished or In-House Components. Required Tooling for Assembly of products. Required Gages for Quality Control on shop floor (standard or specific gages, measurements devices or systems and testing equipment for Assembly and In-House Components) and for Incoming Inspection
Develop the Production Infrastructure and Layout during the Quotation and Serial Development Phase including: Existing site infrastructure and layout. Detailed shop floor layout including material flow, production equipment and assembly lines. Required existing and new infrastructure (including expansion of buildings, floor, electricity, and air supply) and specifications, cost, timing, and potential suppliers
Conduct the FMEA Process during the Serial Development Phase including: Product design including special characteristics. FMEA product. Process Flow Charts. Lessons Learned. Definition of failure modes on working step level according to process flows of Manufacturing, Assembly (including rework), and linked logistics material and purchasing handling)
Support of Sales, Product and Program Management, and Finance
Support of Project and Program Managers, Product Engineering, Advanced and Supplier Quality, Purchasing, Change Management along with Production Site (Launch Managers, Manufacturing and Process Engineers)
Production Component and Equipment Suppliers
Practice and maintain integrity while following Magna’s Charter and Constitution.
Follow Magna’s Code of Conduct and Ethics and related compliance policies.
Supports and adheres to policies, procedures, and operational guidelines related to established quality management system (IATF 16949).
Drive the development of new technologies to improve quality, efficiency and reduce cost.
Comply with safety policies and procedures to ensure duties of self are performed in a safe manner.
Understand applicable Environmental, Health & Safety policies and procedures in the workplace.
Report unsafe conditions immediately.
Report injuries, accidents, illnesses, near misses, property damage immediately.
Follow safety rules.
Comply with requirements for the use or operation of machines or equipment.
Comply with Personal Protective Equipment (PPE) requirements.
Create a positive work environment by demonstrating and sharing functional/technical knowledge.
Develop and maintain a responsive and cooperative working relationship with internal and external customers.
Treat everyone with dignity, trust and respect.
Complete additional duties and responsibilities as assigned.