Product Process Design Lead (Staff Engineer)

Job Description

Title : Staff Engineer Aluminum Product Line

Reports To : Product Engineering Manager

Direct Reports : 0 at start with plan for direct reports in the future

Summary

Our client has an exciting opportunity for an individual seeking a leadership role in our Product Engineering department.

The role is for Staff Engineer responsible for the development of aluminum forged products. The successful candidate will be an individual who has demonstrated success in the design, development, validation, launch and manufacturing of forged aluminum, safety critical components.

Collaborating with key stakeholders within the Company, our customers and supply base, this role will have significant impact on the Company’s growth objective to be the number 1 producer of forged aluminum components.

Company has complete end-to-end engineering capability incl R&D, Testing, Product Design / Development and Full Laboratory support all on site for cincurrent engineering effort-all on site with production operations.

Job Duties

• Design for manufacturability : Collaborating with the Advanced Manufacturing Engineering and the Materials Engineering groups, the individual will work to ensure robust designs are created that allow for optimized manufacturing efficiency such as high OEE, low takt times and top, world class, Quality levels.
• Guide, recommend and support the selection of forging and heat-treating equipment that will ensure repeatable processes and produce parts that demonstrate high standards of product performance.
• Working with in-house Staff Metallurgist, draw on your knowledge of aluminum alloys and the aluminum supply base to recommend material grades for products and processes.
• Provide support in the development of new aluminum alloys for higher stress applications. Develop the product experimental and validation methods needed to ensure manufacturing and part performance objectives are met without negatively impacting corrosion resistance or other key functional attributes.
• Consult with industry specialists and implement best practices into designs and manufacturing processes.
• Interact as a key technical liaison with customers. Convey company’s abilities, knowledge, and program status to elevate customer confidence.

Create and communicate technical presentations. Seek and support new business opportunities.

• Coordinate DVPR, PVPR test programs. Work with resident Durability and Metallurgical laboratories to generate professional, investigative reports which meet and exceed customer expectations.
• Guide and train peers with your knowledge of aluminum manufacturing and design. Support the development of these capabilities throughout the organization.
• Draw on your knowledge of ANSI Y14.5 M drawing standards, to work with resident CAD team to develop 3D and 2D design models.

Review, approve, and release product drawings, and other controlled documents.

• Lead and co-ordinate the prototype build process for new product launches. Use DOE methodology to optimize process parameters in preparation for production.
• Utilize Kaizen and other continuous improvement methodologies to implement product and process improvements. Identify and implement potential cost reduction opportunities.
• Conduct multi-discipline Design Review meetings. Identify issues, risks and implement mitigation measures when and where needed.
• Utilize statistical techniques to analyze results and make data driven decisions.
• Review and resolve product / process change requests submitted by manufacturing, customers, and suppliers.

Requirements

• A minimum 10 years’ experience in the design, development, and manufacturing of forged aluminum components
• Bachelor’s degree in Mechanical Engineering, or related discipline, from an accredited University.
• Applicable post-graduate studies may be credited towards work experience.
• Five to eight year’s experience in the design and manufacture of safety critical automotive components preferably in chassis and suspension components.
• Possession of strong communication skills, both written and verbal. Demonstrated ability to deal effectively with customers, vendors and cross functionally within the organization.
• Proven leadership skills and strong technical acumen.
• The ability to write dFMEAs and support the creation of pFMEAs in a team environment.
• Familiarity with the APQP process with having exposure working in a gate driven Program Management system
• Familiarity with the following software applications is preferred :
• Microsoft Office Suite
• Minitab or other statistical analysis software
• Microsoft Project
• A working knowledge of Catia V5 is considered an asset.
• A working knowledge of Finite Element Analysis tools is considered an asset.
• Basic understanding of FMVSS and other safety standards
• Willingness to travel on an as-needed basis. Travel will be occasional and primarily in the Southern Ontario, Michigan corridor.

Some international travel may be required.

Geographic Region

SW Ontario