JOB SUMMARY:Process Design Engineer is responsible to analyze the manufacturability, tooling feasibility and design the Manufacturing process for all new programs until the PPAP submission. Also utilize the Lean and Six Sigma tools to optimize the production processes to yield higher efficiencies.
ESSENTIAL FUNCTIONS:- Coordinate project needs with sales, operations, automation, quality etc. as necessary to ensure success of project launch and process methods until PPAP submission.
- Create and interpret the mechanical drawings with appropriate Geometric Dimensioning & Tolerancing (GD &T) as per ASME Y14.5 2009 to ensure the form, fit and function of the part.
- Design the fixtures, gages necessary to aid the manufacturing process of the parts. Also perform design modifications to the part designs thereby making them manufacturing friendly.
- Work very close with QE and QA in APQP review process until the project release to Serial Production.
- Analyze the feasibility for customer part designs in terms of Design of Manufacturability (DFM), Design for Quality (DFM) and Design for Functionality (DFF) and take necessary actions to minimize the risks.
- Design the manufacturing Process and prepare all required documentation such as Control Plan’s, Process Failure modes and Effects Analysis (PFMEA), Work instructions etc.
- Perform Statistical analysis such as Process Capability (Cp, Cpk), Control charts, Normality Tests, ANOVA etc. using Minitab software
- Conduct Measurement system Analysis (MSA) such as Gage Repeatability & Reproducibility (Gage R & R) and Linearity study on the measurement equipment to ensure their integrity.
- Utilize problem solving methodologies such as Red-X, A3, 8D to drive improvements.
- Perform Internal Audits such as ISO 140001, ISO 90001 & IATF 16949, Layered Process Audits (LPA), Gemba Walks as per the schedule, document findings and follow through until closure.
- Program inspection routines on Co-ordinate Measurement Machine (CMM) and OGP (vision System) to aid in the measurement process.
- Conduct equipment validation process with master samples and documentation.
- Assist in implementation of the Internal Business Systems (IBS)