Engineer, Process

ABC Technologies is a leading global manufacturer and supplier of custom, highly engineered, technical plastics, and light-weight innovations to the North American light vehicle industry. Serving more than 25 major original equipment manufacturer customers in 7 countries, the Company is Molding The Future and is strategically placed to offer vertically integrated product and process solutions through a skilled workforce of over 11,000 team members. Additional information about the Company can be found at www.abctechnologies.com.

Job Summary:

A Process Engineer in a plant plays a key role in ensuring the efficiency, quality, and safety of manufacturing processes. The purpose of the Process Engineer position is to monitor all processes to ensure customer needs, drawing specifications are being met and to participate in continuous improvement projects as required. It will also ensure all documentation is kept complying with TS16949 standards.

Overall, Process Engineers play a vital role in ensuring the reliability, efficiency, and quality of manufacturing processes, contributing to the overall success and competitiveness of the plant. They combine technical expertise with analytical skills and a commitment to continuous improvement to optimize production operations and deliver high-quality automotive parts to customers.

Job Responsibilities:

Your supervisor may from time to time ask you to perform other related duties not specifically included in this job description. This job's key responsibilities include:

• Process Optimization: Analyzing existing manufacturing processes to identify areas for improvement in efficiency, productivity, and cost-effectiveness. Support Process Technicians as needed. Must troubleshoot and diagnose processing issues. Developing and implementing process improvements, including changes to equipment, materials, layout, or workflow, to optimize manufacturing operations. Conducting time studies, cycle time analysis, and process simulations to identify bottlenecks and inefficiencies in production processes. Conduct process studies and make recommendations to the team that will improve process, machine, and material improvements to enhance manufacturing and maintenance efficiencies.

• Team Collaboration: Work with internal and external teams to ensure the proper tools, fixtures, and additional equipment is in place to meet the required productivity, quality objectives, and cost objectives. Verify with commercial(sales) side that we are doing what our established BOM requirements are. Be a part of tooling, fixtures, gauges, and other equipment development and design. Ensuring that the company will be able to meet productivity requirements, quality objectives, and cost objectives. Communicate with the ABC Technologies team and the customer to ensure both parties are aware of the program status.

• Quality Assurance: Establishing quality control measures and standards to ensure that automotive parts meet specifications and customer requirements. Developing and implementing quality inspection processes, procedures, and tests to detect and prevent defects in manufactured parts. Investigating root causes of quality issues or non-conformances and implementing corrective and preventive actions to address them. Assist in development and implementation APQP documents such as Flow Chart, PFMEA, Standardized Work Instructions, Open Issues List, and other documentation utilizing a team approach. Ensure that all aspects of the Process Engineering Department are in full compliance with the Quality System established and they are being followed.

• Equipment Maintenance and Reliability: Collaborating with maintenance teams to ensure that manufacturing equipment and machinery are properly maintained and optimized for performance. Developing and implementing preventive maintenance programs to minimize downtime and maximize equipment reliability. Analyzing equipment performance data, conducting failure mode and effects analysis (FMEA), and implementing reliability improvement initiatives to enhance equipment uptime and longevity.

• Safety and Regulatory Compliance: Ensuring compliance with safety regulations, environmental standards, and industry best practices in manufacturing operations. Identifying and mitigating safety hazards and ergonomic risks associated with manufacturing processes. Conducting safety audits, inspections, and training programs to promote a culture of safety and continuous improvement.

• Data Analysis and Reporting: Collecting and analyzing data related to manufacturing processes, including production output, quality metrics, downtime, and scrap rates. Generating reports, dashboards, and performance metrics to track process performance, identify trends, and make data-driven decisions for process optimization. Presenting findings and recommendations to management and stakeholders, communicating insights and opportunities for improvement.

• Continuous Improvement: Leading or participating in continuous improvement initiatives such as lean manufacturing, Six Sigma, or Kaizen events to drive efficiency gains and cost savings. Engaging with cross-functional teams to implement best practices, standardize processes, and foster a culture of continuous improvement throughout the organization. Utilize 5S, Lean Manufacturing, and Standard Work to improve manufacturing efficiencies, floor space, and housekeeping.

• Planning: Participate in development of the annual business plan, long range plan, and other action-oriented plans as directed by management.

Job Qualifications:

• Education: Engineering degree or equivalent experience.

• Skills & Experience

• Technical Skills: 2-4 years of Injection/Blow Molding experience in the automotive industry

• Understanding of Manufacturing Processes: Knowledge of various manufacturing processes used in automotive part production, including casting, machining, forming, welding, and assembly.

• CAD/CAM Skills: Proficiency in computer-aided design (CAD) software and computer-aided manufacturing (CAM) software for designing parts, creating tooling/fixtures, and programming CNC machines.

• Process Optimization: Ability to analyze manufacturing processes, identify inefficiencies or bottlenecks, and develop and implement process improvements to enhance efficiency, productivity, and quality.

• Quality Control and Assurance: Understanding of quality control methods, statistical process control (SPC), and quality assurance principles to ensure that automotive parts meet specifications and customer requirements.

• Problem-Solving: Strong problem-solving skills to troubleshoot process issues, identify root causes of defects or non-conformances, and implement corrective and preventive actions.

• Data Analysis: Proficiency in data analysis tools and techniques to collect, analyze, and interpret data related to manufacturing processes, including production metrics, quality indicators, and performance trends.

Behavioural Expectations:

• Safety-First

• A safety-first mindset is a proactive approach to safety, where all employees keep an eye out for safety issues and avoid potentially dangerous situation which could likely cause danger, risk, or injury. This also means that everyone has responsibility for safety regardless of role, level, title, or job.

• Continuous Improvements

• Suggest every employee, everywhere is always looking for ways we can improve and standardize our work even when everything is going well. By doing so, it will drive consistent progress toward improved business performance and will tap into people's desire to be the best at what they do.

• Compliance

• Employee compliance is achieved when workers are familiar with all the laws that govern their industry or job and know how to conduct business in an ethical manner. It often requires procedural training and encouragement to learn from mistakes.

• Driving Results

• Everyone knows their role and is accountable for driving their work to achieve a common goal.

• ONE Team - being part of a group that shares strong relationships, trust, respect, and a common vision for what "good" looks like. One team means supporting and relying on one another to achieve to drive the overall business priorities and meet our customer commitments.

Working Conditions:

• Manufacturing Environment: This role typically works in a manufacturing facility where automotive parts are produced. This environment may involve exposure to noise, heat, dust, and other potential hazards associated with industrial settings.

• Shift Work: Automotive parts manufacturing companies often operate on multiple shifts to maximize production output. As a result, this role may be required to work evening, night, or weekend shifts to support continuous manufacturing operations.

• Physical Demands: The job may involve physical tasks such as lifting, bending, and standing for extended periods.

• Manual Dexterity: Good hand-eye coordination and manual dexterity are important.

• Tolerance to Temperature and Noise: Automotive manufacturing environments can be noisy, and temperature conditions may vary. Technicians should be able to work in these conditions comfortably and safely.

• Use of Personal Protective Equipment (PPE): Technicians must be willing to use and comply with the use of PPE, such as safety glasses, ear protection, gloves, and other safety gear, as required by the manufacturing environment.

• Travel: Must be able to travel from time to time to assist with customer and / or quality issues.

Environmental, Health and Safety Expectations:

Employee Responsibilities:

• Work in compliance with ABC Standards, EHS Policies, Local, Regional and Federal acts, bylaws, and regulations.

• Report any spills or leaks immediately.

• Use personal protective equipment and clothing as required.

• All Employees shall follow Site Workplace Safety Guidelines.

• No Employee shall remove or make ineffective any protective device and must report missing or damaged protective devices.

• No Employee shall use or operate any equipment, machine, or device in a manner that may endanger themself or another worker, including the operation of equipment, machine, or device without proper training or certifications where required.

• No Employee shall engage in horseplay or unsafe acts.

• Employees must immediately report any hazard(s), unsafe act/condition, near miss or incident regardless of severity to their Group Leader.

• All Employees must maintain a drug and alcohol-free workplace in compliance with the substance abuse policy.

Security and Housekeeping:

• Ensure visitors and contractors follow the Contractor Management Policies / Site-specific Procedures.

• All Employees must use the designated employee entrance and exit doors. Under no circumstances can employees prop or cause to remain open any entrance or exit door that could permit entry to the facility for unauthorized individuals.

• All employees shall ensure the building is always clean and a safe workplace.

• No food or drink is permitted in the warehouse or production area, unless in a spill proof container. All other food and drink items must remain in the designated break areas.

Why ABC?

In addition to a workplace that emphasizes respect, teamwork and personal and professional growth, ABC Technologies offers a broad range of health, wellness and financial benefits that promote the physical, mental and financial wellbeing of our employees and help them bring their best self to work, including:

• Competitive compensation package

• Employee Group Benefits

• Retirement Saving Program (401K)

• Educational Assistance Program

• Home, Auto and Pet Insurance

• Vehicle Purchase Discounts

• Employee and Family Assistance Program

• Annual increases in PTO

• Internal job opportunities

• Social events throughout the year