Industrialization & Design for Manufacturability- Own the industrialization of all Anderson-engineered product (ETO, CTO and MTS), ensuring master routings, raw material definitions and tooling and fixturing requirements are established and maintained.
- Lead formal design-for-manufacturability (DFM) reviews with Design Engineering before drawing release, confirming each part can be machined, welded, fabricated, heat treated, ground and assembled with Anderson’s equipment, capabilities and suppliers.
- Identify and document design changes that reduce cost, operations, setups, unnecessarily tight tolerances and lead time without affecting form, fit or function, and track each recommendation to an approved decision.
- Lead make vs. buy analysis for new and existing parts using capacity, cost and lead-time data, and present recommendations to Operations and Supply Chain.
- Ensure work instructions, fixturing, tooling and inspection requirements are defined for new product, and that first-article results are reviewed and closed out.
Routings, Standards & Costing Accuracy- Ensure routings are set up and maintained for all manufactured product, including outside services and raw materials, and hold the Industrial Engineering team responsible for keeping them complete and current.
- Own the accuracy of all manufacturing standards in the ERP: operations and sequence, work centers, process (run) times, setup times, outside service operations and bills of material.
- Help process Engineering Change Orders (ECOs), ensuring routings and standards are updated accurately and on time, and that work in process (WIP) affected by the change is updated or receives a final disposition.
- Ensure raw material is correctly defined for every manufactured part (material grade/specification, form, size, cut length and quantity per part) and that raw material cost on the bill of material is current.
- Ensure outside service operations (e.g., heat treat, plating, coating, grinding) are defined in the routing with the correct supplier, specification, lead time and cost, in coordination with Supply Chain.
- Establish and maintain a documented method for setting standards on new work, and a review schedule that compares standard to actual performance, prioritizing high-volume and high-variance parts.
- Partner with Accounting to ensure standards support accurate product costing under Anderson’s costing method; investigate and explain standard-driven cost variances and correct the root cause.
- Provide Sales and Estimating with documented labor, outside service and material estimates for new quotes and engineered orders.
Lot Sizing & Safety Stock- Establish economic cycle quantities for manufactured parts, balancing setup cost against inventory cost, to ensure accurate costing and profitability.
- Review minimum and maximum lot sizes on a regular basis and adjust them as demand, setup times and costs change.
- Adjust safety stock levels as forecasts are submitted by Sales, in coordination with Supply Chain and Production Planning.
Nonconforming Product- Lead the engineering disposition of nonconforming product to use as is, rework/repair to manufacture, scrap or return to vendor, while ensuring every deviation is captured, documented and approved in alignment with Anderson International processes and standards.
- Ensure each disposition includes engineering justification, any required rework or repair instructions, and the impact on form, fit, function and customer requirements.
- Ensure repair and rework work orders are created for nonconforming product so rework labor and material are captured.
- Ensure dispositions are completed within the timeframe defined by Anderson’s nonconforming material process so production and shipments are not held up.
- Partner with Quality, Operations and suppliers on root cause and corrective action, and ensure drawings, routings, work instructions and standards are updated so the same nonconformance does not repeat.
- Track and report nonconformance trends by part, process and supplier to drive engineering corrective action.
Supplier Qualification- Assess and approve manufacturing control plans submitted by suppliers.
- Help perform supplier site audits to qualify suppliers for AIC’s Approved Supplier List (ASL).
Continuous Improvement Support (5S & Lean)- Support the continuous improvement, 5S and lean manufacturing objectives led by the Quality & Continuous Improvement department with industrial engineering resources, data and analysis.
- Provide industrial engineering input on improvement projects for cycle time, setup reduction, flow, layout, ergonomics, safety and quality, and ensure resulting changes are reflected in routings and standards.
- Provide engineering analysis for capital equipment justification, plant layout changes and new equipment launches, including updating routings and standards when processes move to new equipment.
- Use labor reporting, scrap, variance and throughput data to identify priorities and verify results.
Leadership & Team Management- Hire, train and develop two Industrial Engineers and hold them responsible for their work; set written priorities, assign ownership by product line or area, and review performance against department KPIs.
- Assign and balance industrial engineering workload across product lines and shifts, including support for 3rd shift.
- Set, track and report department KPIs, such as routing completeness, standards accuracy (standard vs. actual), on-time release to production, nonconformance disposition time and open nonconformance aging.
- Attend the daily Gemba walk and contribute to the immediate priorities of safety, manufacturing and production.
- Represent Industrial Engineering in production, engineering, project and ERP meetings, and escalate risks to schedule, cost or quality early.
- Ensure the Industrial Engineering team supports the Manufacturing Manager, Production Managers and direct labor with technical questions on drawings, work instructions and standard operating procedures for equipment.
- Support the production floor directly, and provide technical support and guidance to the Director of Operations, Manufacturing Manager and CNC programmers.
|
Education- Bachelor’s degree in Industrial, Manufacturing or Mechanical Engineering, or related field. Equivalent hands-on manufacturing engineering experience will be considered.
Experience- 8+ years of manufacturing or industrial engineering experience in a metalworking or capital equipment environment, with at least 3 years leading engineers or technical staff.
- Prior knowledge of machining, welding, fabricating, assembly, heat treat and grinding is required.
- Proven experience building and maintaining routings and bills of material, setting labor standards, defining outside services and raw material, and supporting product costing.
- Proven experience leading nonconforming material review and engineering disposition.
- Experience with moderately large, fairly complex production of mechanical capital equipment is required.
- Experience in an ETO / CTO / low-volume, high-mix environment strongly preferred.
Knowledge & Skills- Strong blueprint reading and GD&T; working knowledge of CAD (SolidWorks or similar) and CNC programming concepts.
- Working knowledge of ERP/MRP systems, including routing, bill of material and costing functions (Epicor experience a plus).
- Root cause analysis and problem-solving tools; working knowledge of lean manufacturing and 5S.
- Proficient in Excel and data analysis.
- Strong leader and communicator, comfortable on the shop floor and in front of leadership; able to hold people responsible and work across departments.
|
