ROLE SUMMARY<\/p>\n
\tThe Engineering Specialist \u2013 Process: Leads Manufacturing Process Engineering for Final Assembly (Trim\/Chassis), driving continuous improvement in safety, quality, and productivity. This role is central to program launch management and readiness, overseeing all aspects from initial planning to production.\u00a0<\/p>\n
POSITION DETAILS – Manufacturing Process Engineering & Continuous Improvement:<\/p>\n
\tLead Manufacturing Process Engineering activities for Final Assembly, with a focus on Trim and Chassis Assembly operations.
\n\tDrive continuous improvement in safety, quality, and productivity across all manufacturing processes.
\n\tApply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products.
\n\tDevelop action plans to investigate and prioritize quality concerns and verify corrective actions on internal processes and supplier processes.
\n\tConduct process audits to ensure process discipline consistent with Vehicle Operations guidelines, adherence to process outline, and drive continuous improvement.
\n\tConduct job ergonomic evaluations and deliver corrective actions as required.
\n\tAnalyse vehicle inventory root causes; engage in mapping and corrective actions to reduce vehicle inventory.
\n\tDeliver capable processes and tools for Trim and Chassis Assembly operations.
\n\tLead in resolving assembly-related concerns. Lead variability reduction and lean manufacturing initiatives and best practices.
\n\tIdentify throughput constraints and drive root cause improvements.
\n\tIdentify and drive to closure all FRC issues within Chassis and\/or Trim areas.
\n\tMaintain fixture\/jig integrity within your responsible zone along with required backups.
\n\tIdentify and close all control plan items marked as red within your respective zones.
\n\tSupport MTC changes and efficiency activities within Chassis and\/or Trim areas.
\n\tSupport warranty investigations in Chassis and\/or Trim areas.<\/p>\n
Program Launch Management & Readiness:<\/p>\n
\tConfirm layouts, material flow diagrams, and pedestrian flow meet standards for new programs.
\n\tEnsure new parts are plotted and will fit on the station, and layout demarcations meet layout standards (CLL).
\n\tSupport all aspects of build events (Slow Build, TT, PP, MP1, FCPA, FER), including participating and leading “war room” meetings, capturing and binning build issues, ensuring robust 8D (Quality Operating System)\/5D \u00a0 \u00a0 \u00a0 \u00a0 \u00a0(Launch Quality Operating System 800)\/4D (Manufacturing Operating System) closure actions, and sending out quality scorecards and night letters.
\n\tReview changes in product and process that may impact the plant manufacturing process or operational plan, delivering programs within current model constraints (operational costs including lost units, scrap, industrial material, labour).
\n\tConduct content change analysis with the launch team to understand the impact on processes and facilities,ensuring appropriate countermeasures and training are implemented.
\n\tEnsure Zoning is completed prior to all GDPS (Global Development Process System) milestones (TT, PP, MP1) with no new launch-related open issues and ensure carry-over items are moved to DCC or MCC for the department.
\n\tLead the Workstation Readiness Assessment (WSR) as per standard, ensuring zero open issues, and that the WSR is followed using the appropriate check sheet three weeks before every build phase.
\n\tEnsure Part sign-off prior to build phase for all Non-PPAP (Production Part Approval Process) parts and ensure part delivery to team members doesn\u2019t cause any damages or issues, coordinating with MP&L (Material Planning & Logistics) to isolate launch parts.<\/p>\n
Quality Operating Systems (QOS) & Compliance:<\/p>\n
\tEnsure that Plant QOS processes are active and complete, covering gauging strategy, equipment capability,traceability (QLSCM), DCP (Data Collection Point), OIS (Operator Instruction Sheet)\/WES (Work Element Sheet),QCM (Quality Control Method), error-proofing systems, and inspection processes.
\n\tEnsure correct measurement system\/gauge selection, Gauge R&R study completion, functional QLS systems with appropriate definitions, CDC configuration to confirm traceability, part traceability on EP (Error Proofing),and calibration of DC tools and bench calibration.
\n\tEnsure QCM updates are in line with new content and able to assist build, ensure all items from the control plan are implemented and validated during build, ensure OIS\/WES is up to date and released on Launch APT plan, ensure EQI layout is in line with content change, and adapt QCM’s based upon missed inspection and perform quality recalibration.
\n\tReview and understand the High Hurts Matrix, ensuring previous High Hurts are implemented to upcoming programs and validated, and populate\/hand over the HH list with CFT (Cross-Functional Team) into a consolidated list to PVT-ME \/ VME.
\n\tSupport Whiteboard meetings to ensure all issues have ICA (Interim Containment Action)\/PCA (Permanent Corrective Action) within 24 hours, and support achieving, verifying, and maintaining all production quality requirements during build phases.
\n\tEnsure that teardown results and test result corrective actions are incorporated into the manufacturing and EOL (End of Line) testing process.<\/p>\n
Safety, Health & Environmental Compliance:<\/p>\n
\tEnsure that Risk Assessments are completed for the Design, Build, Modification, and Commissioning of Equipment (Concept, Design, Build and Runoff, Launch phase, Modifications to existing equipment).
\n\tEnsure that Pre Task Assessment is signed off for skilled trades\/contractor work (review at specified intervals).
\n\tSupport PROTAG sign-off to plan, guiding plant personnel (Plant Operations and Skilled Trades) through White-to-Pink, Pink-to-Yellow, and Yellow-to-Green phases, and reviewing PROTAG status and punch list completion.
\n\tEnsure the work area has appropriate signage posted and clearly visible in case of exposure to hazards,including approved Toxicology (TOX) numbers, identifying new chemicals and ensuring proper loading \/labelling as per procedure (FAS08-252 Chemical Hazard Communication Standard).
\n\tEnsure Job Safety Analysis (JSA) is completed for processes prior to TT build.
\n\tEnsure that BBQ (Bypass, Backup, or Quick response) and all backup tooling is available per the BBQ strategy(MOS BBQ Assessment form).
\n\tEnsure compliance to Plant, Corporate, Governmental, and Environmental standards.
\n\tSupport ISO 14001 compliance and support internal ISO auditing and compliance as required.
\n\tEnsure safe and proper disposal of equipment as applicable.
\n\tEnsure equipment power consumption is minimized when equipment and facilities are not being used (auto shutdown mode\/turn off when not being utilized).
\n\tEnsure that handling, cleaning, and corrosion protection of metal parts are followed.<\/p>\n
Cost Initiatives:<\/p>\n
\tLead one cost-saving project to implementation per year
\n\tImplement one Kaizen project per month.
\n\tCommunication and working relationships: This role requires extensive collaboration and communication with Manufacturing Leadership, Quality, Production, Maintenance, LPWR, Product Development, Vehicle Manufacturing Engineering (VME), external suppliers, and cross-functional teams to ensure seamless operations and successful program launches.<\/p>\n
Responsibilities
\nPERFORMANCE MEASURES\/ SUCCESS CRITERIA:<\/p>\n
\tImplement Zero Defect \/ Error Proofed Processes.
\n\tNo downtime related to jig\/fixtures within Chassis and\/or trim areas.
\n\tDeliver a zone FRC greater than 97%.
\n\tEnsure process audits are conducted within specified timing as per company policy.
\n\tComplete a minimum of two Green Belt projects per year.
\n\tEnsure within a two-year period from enrolment, that candidate is Green Belt certified.
\n\tLayouts, material flow diagrams, and pedestrian flow meet standards.
\n\tRisk assessments are completed for design, build, modification, and commissioning of equipment.
\n\tPre-Task Assessment signed off for skilled trades\/contractor work.
\n\tPROTAG sign-off supported to plan, and punch list items followed to completion.
\n\tJSA completed for processes prior to TT build.
\n\tRobust 8D\/5D\/4D closure actions for build issues.
\n\tPlant QOS processes active and complete (Gauging strategy, equipment capability, traceability\/QLS; DCP, OIS\/WES, QCM, Error Proofing systems operational, Inspection Processes).
\n\tHigh Hurts Matrix reviewed and updated.
\n\tAchieve, verify, and maintain all production quality requirements during build phase.
\n\tWhiteboard, AIMs and build issue manufacturing ensure all issues have ICA\/PCA.
\n\tBuild Quality Metrics for each build milestone.
\n\tTeardown results and test result corrective actions incorporated.
\n\tProgram delivered within current model constraints, with content analysis complete.
\n\tZoning completed prior to GDPS milestones with no new launch-related open issues.
\n\tWorkstation Readiness Assessment (WSR) completed with zero open issues prior to GDPS milestones.
\n\tPart sign-off prior to build phase for all Non-PPAP parts completed.
\n\tCost-saving projects implementation.
\n\tKaizen projects implementation.
\n\tBBQ and all backup tooling is available.
\n\tEquipment power consumption minimized.<\/p>\n
KNOWLEDGE, SKILLS and ABILITIES (KSA):<\/p>\n
Technical Skills:<\/p>\n
\tLean Manufacturing and Six Sigma experience.
\n\t8D and 5Why corrective action and problem-solving skills.
\n\tLean Tools \u2013 5S, Kanban, Poka-yoke, and Value Stream Mapping.
\n\tDMAIC and DMADV (Design for Six Sigma) Project Methodology experience.
\n\tTQM (Total Quality Management) and Kaizen Methods.
\n\tFMEA (Failure Mode and Effects Analysis), PPAP, and DOEs (Design of Experiments) experience.
\n\tErgonomic analysis knowledge and experience.
\n\tGSPAS\/APT.
\n\tCLL\/Auto CAD.
\n\tWow Falcon \/ WERS.
\n\tIllustration, MOVIS, AIS.
\n\tKnowledge of Plant Layout, Material Flow Diagram, Pedestrian Flow standards (e.g., FAS08-079).
\n\tRisk Assessment methodologies (e.g., FAS08-036).
\n\tPROTAG procedures and sign-off processes.
\n\tChemical Hazard Communication Standard (FAS08-252) and Toxicology (TOX) number management.
\n\tJob Safety Analysis (JSA).
\n\tQuality Operating System (QOS) processes, including Gauging (e.g., PTS02-081ME, PTP07-015), Traceability (e.g., FAP02-007, PTS02-112ME), QLS, CDC, Calibration (e.g., FAP03-015, PTP07-111, PTP07-120),
\n\tHigh Hurts procedures (e.g., PTP02-183ME, LQOS 802).
\n\tExperience with Production FIS\/IIOT systems.
\n\tBuild event management (TT, PP, MP1, FCPA, FER) and related procedures (e.g., PTP02-113ME MLP, PTP03-115 PTR, LQOS 800\/815\/530\/824).
\n\tWorkstation Readiness Assessment (WSR).
\n\tLPWR processes and eFPS.<\/p>\n
Competencies:<\/p>\n
\tEffective oral and written communication skills.
\n\tStrong leadership capabilities (ONE FORD behaviors).
\n\tOutstanding interpersonal, teambuilding, and communication skills.
\n\t\u00a0Ability to deeply understand user intent and provide clear, accurate answers.
\n\tProblem-solving and analytical thinking (8D, 5Why).
\n\tAbility to drive continuous improvement and lean manufacturing initiatives.
\n\tStrong organizational and planning skills.
\n\tResults-oriented with a focus on meeting KPIs.
\n\tCollaboration across diverse teams.
\n\tProactive in identifying and addressing challenges.
\n\tGeneral attributes: (As implied by the above)
\n\t\u00a0Linguistic skills: Effective oral and written communication skills<\/p>\n
Qualifications
\nQUALIFICATIONS and EXPERIENCE \u00a0\u00a0<\/p>\n
Preferred Requirements:<\/p>\n
\tEducation: Bachelor\u2019s degree in Mechanical \/ Electrical or Industrial engineering.\u00a0
\n\tExperience: 5+ yrs of related experience.
\n\tA certified green belt has an advantage.
\n\tAriba access and use has advantage.
\n\tSuccessful candidate must be able to demonstrate leadership in ONE FORD (leadership) behaviors combined with outstanding interpersonal, teambuilding, and communication skills.<\/p>\n
go to method of application \u00bb<\/p>\n
Apply via company website ( N \/ A ) or<\/p>\n
<\/p>\n","protected":false},"author":2,"featured_media":0,"template":"","meta":{"_promoted":"","_job_location":"","_application":"","_company_name":"Ford Motor Company of Southern Africa","_company_website":"http:\/\/N%20\/%20A","_company_tagline":"Ford Motor Company is a global company based in Dearborn, Michigan. The company designs, manufactures, markets and services a full line of Ford cars, trucks, SUVs, electrified vehicles and Lincoln luxury vehicles, provides financial services through Ford Motor Credit Company and is pursuing leadersh... read moreip positions in electrification, autonomous vehicles and mobility solutions. Ford employs approximately 200,000 people worldwide. For more information regarding Ford, its products and Ford Motor Credit Company, please visit www.corporate.ford.com.","_company_twitter":"","_company_video":"","_filled":0,"_featured":0,"_remote_position":0,"_job_salary":"","_job_salary_currency":"","_job_salary_unit":""},"job_listing_region":[11],"job-types":[12],"class_list":["post-19589","job_listing","type-job_listing","status-expired","hentry","job_listing_region-gauteng","job-type-full-time"],"jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/jobs.dataaxisnode.com\/southafrica\/wp-json\/wp\/v2\/job-listings\/19589","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/jobs.dataaxisnode.com\/southafrica\/wp-json\/wp\/v2\/job-listings"}],"about":[{"href":"https:\/\/jobs.dataaxisnode.com\/southafrica\/wp-json\/wp\/v2\/types\/job_listing"}],"author":[{"embeddable":true,"href":"https:\/\/jobs.dataaxisnode.com\/southafrica\/wp-json\/wp\/v2\/users\/2"}],"wp:attachment":[{"href":"https:\/\/jobs.dataaxisnode.com\/southafrica\/wp-json\/wp\/v2\/media?parent=19589"}],"wp:term":[{"taxonomy":"job_listing_region","embeddable":true,"href":"https:\/\/jobs.dataaxisnode.com\/southafrica\/wp-json\/wp\/v2\/job_listing_region?post=19589"},{"taxonomy":"job_listing_type","embeddable":true,"href":"https:\/\/jobs.dataaxisnode.com\/southafrica\/wp-json\/wp\/v2\/job-types?post=19589"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}