MANUFACTURING SYSTEMS ENGINEER - LOGIN Consulting Services (Northern/Huntsville, Alabama)

POSITION OPEN AS OF NOVEMBER 16.

Major aerospace company in Huntsville has a 6+ month contract available for a Manufacturing Systems Engineer. The Candidate must be a responsible Manufacturing Engineering person to co-ordinate with manufacturing partner in overseeing their manufacturing process definitions and detailed workings, be able to come up with component and assembly costs and tooling investment costs. To lead technical negotiations to get the cost of all manufactured products in line with our targets.

Roles and responsibilities the Manufacturing Systems Engineer:

1. Should be familiar and experienced with Manufacturing Systems Engineering (MSE) activities in a Mass manufacturing environment.
2. Experienced with process design for large sized components and assemblies and large volume production (about 100 assemblies a day)
3. Should be experienced with extensive standard Sheet metal processing and machining (can be limited) processes.
4. Co-ordinate and work closely with outside consultants (PA Consultants) to gather knowledge on manufacturing and assembly related activities.
5. Co-ordinate and work closely with outside manufacturing partner to gather knowledge on most of the manufacturing and assembly related activities.
6. The manufacturing partner is responsible for process design, manufacturing, assembly and delivery of Heliostat assemblies to the field as required. The manufacturing support person*s role is a supporting role to the manufacturing partner. Pick up the process knowledge from Manufacturing partner and help identify and develop another manufacturing partner for future US plants as needed.
7. Co-ordinate with design team members for aiding design for manufacturing.
8. Able to communicate with manufacturing partner process engineers.
9. Knowledgeable of plant layout designs. Discuss with manufacturing partner on plant layouts and suggest improvements / changes.
10. Knowledgeable of production planning, cycle time calculations, balancing of manufacturing and assembly lines.
11. Deciding on effective use of resources like raw material, equipment and labor.
12. Reviewing and advising on the work of manufacturing partner*s process engineers.
13. Knowledgeable with manufacturing machine capabilities, assembly process capabilities.
14. Knowledgeable with tooling design for fabrication and assembly and in-line testing.
15. Knowledgeable with Material handling and automation in fabrication and assembly lines.
16. Knowledgeable in specifying and procuring Tools, Jigs, Fixtures and GSE (Ground Support Equipments) for fabrication and assembly operations in a mass manufacturing environment.
17. Knowledgeable in establishing assembly procedures and Test plan and procedures.
18. Familiar with safety and environmental hazard requirements in manufacturing and assembly lines.
19. Experience in carrying out PFMEA (Process Failure Mode Effective Analysis)
20. Should be able to suggest improvements for productivity improvements in fabrication and assembly lines to the manufacturing partner.
21. Defining requirements and sourcing experience for manufacturing and assembly equipments.
22. Establishing and implementing quality systems in manufacturing environment.
23. Knowledgeable with all statistical process control (SPC) tools like process control charts, scatter diagrams, Histograms, etc., and Statistical Quality Control (SQC) tools like lot acceptance sampling, etc.,
24. Knowledgeable with APQP (Advanced Product Quality Planning) process which includes FMEA, MSA (Measurement Systems Analysis), SPC and PPAP (Production Part Approval Process) processes.
25. Knowledgeable with Gauge R&R (Repeatability and Reproducibility) studies,
26. Co-ordinate and guide design engineers in developing the design for manufacturability (DFMA).
27. Knowledgeable with manufacturing process capabilities in terms of maintaining required tolerances and repeatability on a mass manufacturing environment.
28. Able to come up with manufacturing process cost estimates and production output estimates of large sized fabrications and assembly processes, considering optimum product cost, optimum risk and schedule.
29. Able to identify process risks and suggest mitigation techniques to overcome the risks for fabrication and assembly.
30. Make suggestion on various component supplier selection process.
31. Able to contribute to the preparation of contract to the manufacturing partner.
32. Identify and contribute to the manufacturing partner on in-line testing requirements during the fabrication and assembly process.
33. Manage integration with the team and manufacturing partner.
34. Establish logistics with manufacturing partner.
35. Provide and maintain Overall product costing (based on process cost estimates and actual quotes from manufacturing partner)
36. Co-ordinate with team members for procurement of material for Prototype and Qualification units.
37. Co-ordinate with team members for identification and purchase of Tools, fixtures for assembly and test activities for prototype and qualification units.
38. Co-ordinate with assembly and test team in establishing assembly processes in line with the mass production assembly process.
39. Knowledgeable with MRP (Material Requirements Planning) for production planning and Inventory control system.
40. Be able to extract Master Production Schedule (MPS) from Master program schedule.
41. Maintain BOM from design inputs.
42. Co-ordinate with outside Manufacturing partner for effective execution of the manufacturing (fabrication and assembly) activity.
43. Ensure materials and products are available for production and delivery to manufacturing partner.
44. Maintain the lowest possible level of inventory.
45. Ensure schedule slippages and associated program risks are minimized.
46. Be able to make suggestion for overall manufacturing strategy (whether the material should be processed by the manufacturing partner or procured from other suppliers, etc.,)
47. Generate periodic reports on manufacturing activity.
48. Co-ordinate with manufacturing partner on material and fabrication and assembly process workmanship related Guarantee / Warranty claims from customer.

Extensive mass manufacturing experience in Automotive or similar large sized sheet metal fabrication and assembly is preferred as is experience in setting up manufacturing and assembly lines for large volume production. The Candidate should be able to do cost estimates for components and tooling as well as process procedure documentation.

The Candidate should have an education in Manufacturing Systems Engineering. Must have the ability to work with the design team in US and overseas with the manufacturing partner.