Senior Manufacturing Engineer

Senior Manufacturing Engineer
Elmdon, Birmingham

Main Purpose of the Job:

Responsible for implementation of production processes and procedures, leading productivity improvements with project based activities, including new product introduction and manufacturing cell design to reduce waste, improve quality and safety, and reduce operating costs. Manage KPIs and ensure preventative actions are taken to maximise success. Responsible for multiple highly complex major projects requiring innovative original solutions where results are key to successful completion of major projects. Work mostly independently with minimal supervision and work is reviewed at project milestones and/or on completion by Senior Management.

Main objectives and results:

• Design new systems and processes for the introduction of new products or for the improvement of existing ones
• Ensure all product and system requirements are taken into account from the initial product conception to the finished result
• Ensure product and process quality to meet specifications required
• Manage budgets and time deadlines
• Tender for equipment to ensure the best quality for best price
• Oversee installation of machinery and equipment
• Maintain statistical and financial records
• Improve manufacturing efficiency by analysing and planning work flow, space requirements and equipment layout
• Remove waste from the processes
• Organise plant start-up and shut-down schedules to ensure minimum loss of production time
• Plan and organise maintenance
• Respond to breakdowns
• Analyse down time and identify trends
• Support and lead continuous improvement, problem solving and process improvement activities
• Carry out FMEAs (Failure Mode Effects Analysis), process documentation and implement improvements
• Poka Yoke (error proofing) where possible to prevent errors
• Investigate production and process issues
• Provide technical support and training
• Write proposals and reports with all necessary backup material
• Develop innovative solutions to unique problems
• Develop and maintain expertise
• Keep up with current and developing engineering trends
• Undertake special projects as required
• Contribute to continuous improvement activities
• Quality control of work by appropriate reviews
• Support and lead process improvement activities
• Write reports and present progress at project meetings and to clients
• Estimate budgets and manpower required for projects
• Achieve goals within budget
• Conduct benchmarking studies to determine best practices/designs and future trends
• Plan projects or subtasks so they may be tracked and presented
• Manage the Key Performance Indicators (KPIs)
• Attend various meetings and action/communicate instructions
• Undertake continuous training and development
• Perform root cause analysis and resolve problems
• Independently determine approach and assigned tasks
  

Relationship Management

• Represent work team at reviews and cross-organisational team meetings
• Attend various meetings and action/communicate instructions
• Liaise and communicate with other departments, customers, suppliers and other service providers
  

Self Management

• Comply with the IAC Health, Safety and Environmental Policies
• Engages interest and participation of others and has a collaborative approach to working with others
• Proactively contributes to the team and actively committed to team development
• Priorities workload in accordance with business requirements

Preferred skills and experience:?

• Exercise substantial initiative/judgement in work methods and interpreting goals
• Understanding manufacturing processes
• Understanding engineering, scientific and other technical information
• Understand lean manufacturing
• Ability to work in a diverse and dynamic environment
• Planning and prioritising activities
• Good communication and interpersonal skills
• Ability to present data effectively
• Problem-solving skills
• Team working skills
• Analytical skills
• Able to effectively train people inside and outside of their work group
• Able to give effective presentations to critical/high level customers and effectively represent work group on review panels and cross-organisational teams
• Can write convincing proposals and reports with all necessary backup material for external consumption
• Ability to present options and persuasively advocate for proposals
• Ability to work constructively with vendors
• Identifies problems and actively devises appropriate solutions
• Relevant manufacturing/engineering degree is preferred, HNC, BTec Professional Level 4 Award or equivalent NVQ Level 4 qualifications.
• Ability to design processes and layouts
• Experience of FMEA (Failure Mode Effects Analysis), Kaizen/A3 (continuous improvement and problem solving) process improvement and Poka Yoke (error proofing) techniques
• Extensive work experience in a high volume manufacturing environment, preferably automotive
• Professional abilities and technical accomplishments are recognised throughout the professional community in the area of expertise
• Understanding of a number of sequencing/manufacturing systems and understands how these multiple systems interact