Senior Technical Quality Engineer
Ford Motor Company of Southern Africa (Pty) Ltd
Total years of experience :10 years, 4 Months
- Drive Flawless Launches at assigned supplier sites, collaborating with Launch STA team (Ex: Schedule A, PPAP (Production Part Approval Process), Supplier Quality Issues resolution). Escalate significant issues promptly and ‘date to green’ plan to appropriate management
- Conduct onsite evaluation visits for Priority commodities as per GPDS supplier engagement process for new programs
- Support Capacity Purchase team in capacity studies interfacing with suppliers and Ford cross-functional teams
- Review supplier incremental tooling work plans compliance to PPAP (Production Part Approval Process) requirements
- Drive capacity/uplift actions implementation with suppliers inline with the GCP study requirements
- Drive Supplier Process capacity issues resolution as needed - Production constraint risk mitigation working with Ford and Supplier teams and manage “date to green” plan
- Monitor supply status of 24/7 roster suppliers and Blue bar status of PPAPs beyond implementation timing
- Review supplier Capacity Analysis Reports (CAR) for compliance to capacity requirements
- Drive robust Supplier Failure Mode Avoidance through PFMEA, SCCAF, CP reviews, Manufacturing feasibility reviews and Health chart deployment as applicable
- Drive Supplier manufacturing health chart compliance and support development of new health charts
- Drive suppliers for Special process compliance with the support of STA Technical Specialists
- Drive continuous improvement in manufacturing excellence with the assigned sites through Q1-MSA deployment, Q1 attainment/ retention, Health chart deployment, Supplier training as required.
- Drive deployment & improvement of Quality performance requirements (Q1, QR, TGW, R/1000, CPU), through Warranty Reduction, Benchmarking, Lean Manufacturing, G8D (Global 8 Disciplines) methodology, PFMEA (Process Failure Mode Effect Analysis), SPC (Statistical Process Control), Gage R&R (Repeatability and Reproducibility), Gage R&R (Repeatability and Reproducibility), etc.) as required
- Drive new supplier site evaluations and Supplier Risk Assessment on new sourcing in support of GCST, identifying Risk Mitigation.
- Drive closure of supplier process Quality issues related to Stop Ship/Build, BSAQ (Balanced Single Agenda for Quality) projects and Field Action Stop Ship/Prevent Action
- Drive compliance to all organizational and corporate training requirements and SIM process compliance.
- Plan and implement training strategy to address technical gaps at supplier organisation to ensure supplier team is equipped with tools to problem solve, track efficiency, understand Technical requirements etc.
- Engage with key executives at the supplier to convey concerns, gaps identified in knowledge and suggest solutions to ensure staff is trained and ready for vehicle launch.
- Track and co-ordinate all Plant Launch activities.
(Launch includes new product introduction and engineering changes along with transfers on products that are currently in production)
- Manage the product launch and plant rearrangement from current to new platforms
- Manage resource and training requirements for pre-builds
- Adherence to Business operating systems and direction setting to the plant team
- Launch cost budget creation and management
- Drive and coordinate Launch review meetings
- Co-ordinate and ensure facility readiness and build dates are met for all sample builds
- Co-ordinate and manage all process sign-off events, power build and run at rate activities
- Support and track PPAP submissions
- Cross functional co-ordination with internal and external stakeholders eg. customer, suppliers and contractors
- Interface with CBU Program Management, internal organisation's departments to ensure timely launch
- Ensure all APQP documents are in place and completed
- Once tools are delivered to the plant the Launch Manager/Plant Manager must approve all engineering change implementation for the purpose of assuring a successful Launch, PPAP or any other customer deliverable.
- Assume ownership of complex projects and oversee execution and delivery;
- Serve as a coach/mentor to others on best practices.
- Signing off New Projects and Ensuring full compliance before it is complete or handed over to Production.
- Assume ownership of complex projects and oversee execution and delivery;
- Serve as a coach/mentor to others on best practices.
- Develop and manage a detailed robust plan and budget for the work undertaken;
- Work with assigned clients as assigned to analyze failure/maintenance historical data and develop appropriate Reliability, Availability and Maintainability (RAM) and Whole Lifecycle Cost models;
- Develop appropriate asset management strategies for our clients’ existing facilities, adopting RCM, RBM or alternative strategies as advised;
- Consolidate, analyze, and interpret unique combinations of equipment, materials, processes and failure mechanisms so as to provide an integrated view for asset management;
- Review downtime data, investigate where necessary and assist in optimizing plant performance;
- Leverage industry experience, equipment knowledge, software know-how, and customer satisfaction skills to deliver a world class solutions to assigned customer accounts;
- Proactively seek ways of improving equipment reliability, planned maintenance, and control systems in the plant;
- Developing Asset Tactics from FMEA and implementing them to the Maintenance system.
- Propose changes and modification to ensure a better performance on production level.
- Foster good IR with Employees during Production Improvements to ensure they understand the process fully and how to operate the machinery safely.
- Signing off New Projects and Ensuring full compliance before it is complete or handed over to Production.
- Implement quality core tools; SPC, MSA, FMEA, Control Plans.
- Maintain Quality systems and concepts.
- Improve/Maintain Manufacturing processes.
- Understand and ensure Customer Specific Requirements are met.
- Signing off New Projects and Ensuring full compliance before it is complete or handed over to Production.
- Plan and assist with the installation of new equipment and process.
- Effective implementation of Engineering Changes, updating of routings and making changes to production processes where necessary.
- Development and implementation of APQP requirements and systems.
- Work Study (Time and Motion) to improve efficiency of the plant.
- Continual analysis of Production Rejects and Scrap Statistics. Making changes to improve Productivity and Quality.
- Propose changes and modification to ensure a better performance on production level.
- Foster good IR with Employees during Production Improvements to ensure they understand the process fully and how to operate the machinery safely.
- Signing off New Projects and Ensuring full compliance before it is complete or handed over to Production.
- Design the Entire Layout for the Production Lines and all Fabricated Equipment needed to Improve Ergonomics for MPT’s (Mass Production Trials).
- Assist Fellow Engineers and Team Members with Tasks for critical projects.
- Responsible for the Ordering of all Machinery and Machinery that needs to be designed in order to Produce Components.
- Problem Solve and Find Dynamic Solutions Daily.
- CMM Scanning and use Reports to Interpret the Accuracy of Components.
- Developing Asset Tactics from FMEA and implementing them to the Maintenance system.
- Development, implementation and maintenance of production standards.
- Analysis of product designs and development, ensuring smooth introduction of products into the manufacturing process.
- Motivation and control of Capital Expenditure projects.
- Plan and assist with the installation of new equipment and process.
- Effective implementation of Engineering Changes, updating of routings and making changes to production processes where necessary.
- Development and implementation of APQP requirements and systems.
- Work Study (Time and Motion) to improve efficiency of the plant.
- Continual analysis of Production Rejects and Scrap Statistics. Making changes to improve Productivity and Quality.
- Propose changes and modification to ensure a better performance on production level.
- Generate reports periodically as requested by the management.
- GMR 2.7 Appointee, In-Charge of all aspects for new and current projects in terms of Equipment and Safety as per the OHS Act.
- G-Coding of Robotic equipment and set up new Machinery from Commissioning to Hand Over
- Control of the CapEx Budget and Physical Assets being purchased.
- Report on Department CapEx activities, Product Sign Offs and New releases.
- Train Personnel on New and Existing Processes, Including the training on New Line Documentation.
- Audit Production Lines and report on prospective upgrades that will increase productivity.
- Build Key Relationships with Internal an d External customers to ensure the smooth roll out of New products and Production Line Upgrades.
- Mentor Graduate Engineers and build key skills in line with the department mission and foster professionalism in line with the company culture.
- Draft Department CapEx Budget and Contribute to the Yearly Financial Budget.
- Conduct Risk Assessments of current processes and Machinery in order to increase safety and ensure compliance to Health and Safety Regulations (OHS Act).
- Foster good IR with Employees during Production Improvements to ensure they understand the process fully and how to operate the machinery safely.
- Signing off New Projects and Ensuring full compliance before it is complete or handed over to Production.
- Rylson8 Maintenance Management trained, Draw up Maintenance strategies upon acquiring new Equipment.
- In-Charge of my own Portfolio of parts for the Project (17 Level 1 Complete Assemblies).
- Produce Parts from Design to Commissioning of Daily Production Line.
- Quality Engineering and Generate Quality Specifications for each Part.
- Commission Robotic Weld Cell and Robotic Weld Assembly Units.
- Project Engineer for Portfolio of Parts.
- Create PPP’s (Production Preparation Plans), SDS’s (Sample Data Sheets), Process Sheets, Timing Plans, and Budgets for my Portfolio of Parts.
- Design the Entire Layout for the Production Lines and all Fabricated Equipment needed to Improve Ergonomics for MPT’s (Mass Production Trials).
- Assist Fellow Engineers and Team Members with Tasks related to 640A.
- Responsible for the Ordering of all Machinery and Machinery that needs to be designed in order to Produce Components.
- Problem Solve and Find Dynamic Solutions Daily.
- CMM Scanning and use Reports to Interpret the Accuracy of Components.
- Project Integration Management: Includes the processes and activities needed to identify, define, combine, unify, and coordinate the various processes and project management activities.
- Project Scope Management: Includes the processes required to ensure that the project includes all the work required, and only the work required, to complete the project successfully.
- Project Time Management: Includes the processes required to manage the timely completion of the project.
- Project Quality Management: Includes the processes and activities of the performing quality policies, objectives, and responsibilities so that the project will satisfy the needs for which it was undertaken.