Senior

Engineer - Process (Battery Pack Value Stream)

Bayan Lepas, Malaysia · On-site

Company Description

Bosch has been present in Malaysia since 1923, represented by Robert Bosch Sdn Bhd, with offices located in Selangor and Penang. In Malaysia, Bosch has diversified businesses in Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The company has three manufacturing plants in Penang providing Car Multimedia, Power Tools and Automotive Steering systems. In 2017, Malaysia contributed sales of RM 615 million (127 million euro) and employed more than 2,800 associates.

Job Description

Job Summary

Responsible for new product line setup and release.
Plan for MAE and EWAK investments related to workstation and accessories for new and existing lines.
Define, purchase, set up, perform trial run and buy off for all workstations and accessories of new products.
Prepare workstations layout, set up workstation, prepare line release documents and perform manufacturing line buy off before Pilot Run or mass production.
Perform Machine and Process Capability Study to ensure machines and processes meet the capability requirement during mass production. Identify and introduce SPC on certain processes whenever applicable.
Train and guide trainers, supervisors and maintenance personnel by transferring technical and process know-how.
Monitor and supervise VSE technician performance to ensure efficiency in value stream improvement activities and processes.
Responsible for process improvement project in production through time study - VT improvement, direct productivity improvement, ergonomic, workstation, machine and technology improvement and update management on the improvement result.
Support production in achieving the effectiveness, output, IDC and quality target through continuous improvement activity.
Liaise with maintenance personnel for maintenance plan set up and spare parts replacement for existing machine used in production.
Involve in failure analysis of production FOR and advise failure analyser on the disposition of the rejected parts.
Involve in Sales Driven Activity (SDA) projects and prepare supplement line release documents for mass production.
Provide support for quality problem resolution through problem solving skills PSS or 8D.
Monitor, report of KPI’s in timely manner and establish action plan.
Optimizing equipment and processes to maximize output & quality and minimize cost.
Mentoring junior Value Stream Engineer (VSE) in new product development processes, improvement activities and system application (eg: SAP, MES system, etc).
Actively participate in internal and external audits by ensuring up-to-date documentation, production system compliance and line readiness to support successful audit execution.
Prepare and deliver improvement project presentations to internal and external stakeholders during reviews, management meetings, and stakeholder visits to ensure alignment and effective communication of project progress and outcomes.
Act as the proxy for the VSE Section Head during periods of absence, ensuring continuity of operations, decision-making and stakeholder communication.

Job Scope

1. New Product Introduction

Responsible to ensure successful transition of new product development from Front End Process (FEP) to manufacturing from C sample build, D sample build to Start of Production (SOP) until product end of life (EOL).
Responsible to ensure product is manufacturing ready from the aspect of manufacturing budgeting, hardware (workstations, line setup, MAE & EWAK), software (machine automation) and people (operator training, technical support competency).
Responsible to ensure the new product transition to manufacturing from SOP able to meet the safety, quality (4Q), cost (Internal Defect Cost, First Pass Yield) and delivery (meeting shipment and delivery target).
Represent manufacturing and contribute in all New Product Startup meeting all critical milestone process in the Project Management Plan e.g. Quality Gates (QG), Product FMEA/DFM and DFMA.
Lead in Process FMEA (from Project Release to Launch Release to Delivery Release), Value Stream Design (VSD), Scaling (SCAL), Lean Line Design (LLD) and Flow-orientated Layout (FOL), working closely with PGL coordinator during the Project Conception phase. (Kickoff to Project Release).
Plan production layout according to BPS principles meeting the cost, quality, time, capacity and logistic requirements (component packing e.g. PFEP info) of the project.
Design manufacturing plan including the budget/cost (as input to project calculation) and design, spec, ordering, setup and qualify for production release of MAE, EWAK, tools, software automation for the new product to meet the safety, ergonomics, ESD protection and process capabilities (Cmk,Cpk & GR&R), which include resistance welding pull off force, technical documentation (PQI, Control Plan, Setup document, In process checklist).
Establish, or optimized if already exists, resistance welding parameter, Line balancing, prepare VT Summary, Operator Balance Chart, Standardize Work with evaluated time studies for new products.
Manage the Engineering build and lead the pre-pilot (C ample), pilot build (D sample) and SOP by schedule, organize, build and analyze according to Project Management Plan and prepare report.
Prepare, update, and issue all Manufacturing Engineering documents: PQI, Visual Aids, In Process Checklist Set Up Plan, Line Balancing, Process FMEA, PQP, PWI, HIRADC and Line Release Documents.
Prepare training module and test paper for new products, train and certify the trainers base on the module.
Train and guide the Production/Process engineer/Supervisor and Maintenance on processes, equipment and machine know how during Pre-Pilot, Pilot build.
Liaise with maintenance section for maintenance plan and spare parts replacements during Line Release process.

2. Operation Support

Responsible for overall manufacturing process compliance from the safety, quality, cost and delivery aspect of direct labour, machine processes and of both direct and indirect material.
Responsible to meet the manufacturing line direct productivity (DP) as the key performance KPI.
Responsible to meet the manufacturing line internal defect cost (IDC), First Pass Yield (FPY) and line failure rates (FOR) as the key performance indicator (KPI).
Plan (or improve the current) and obtain internal buy off production line layout, workplace/workstation layout, material flow planning, space, direct labor headcount and shift requirements, and submit for approval.
Perform big data analysis, review, improve process parameter and monitor all OEE losses of the production lines, including debugging and providing disposition to all fall out rates from production processes or machine testing.
Perform and continuous improvement to the process planning and industrial engineering for existing running products (Line balancing, VT study, improvement & updating).
To review process control parameters, checklist and perform regular process and machine capability study (CpK, CmK, GR&R) on related processes (included welding parameter) in the series production.
To execute the changes of standardize work through time studies, MTM/UAS (Cycle Time module) on process and implement Ergonomics at workstation after KPI improvement.
To optimize line Balancing with the evaluated time studies.
Review, maintain and revise manufacturing engineering documents: Work Instruction, Visual aids, Line balancing, FMEA for process concern after SOP.
To plan and introduce cost reduction activities through process, VT and headcount improvement.
To train and guide Trainers, Supervisors and Direct Operators on manufacturing processes.
To troubleshoot process and quality related problems in production.
To participate in all relevant audits, coordinate in providing and implementing corrective actions.
To participate actively in BPS activity (LLD, QVSM, VSM / VSD).
To participate and support in daily Point CIP, Daily morning meeting (DMM).
To guard and support Value steam engineer/ FPV on manufacturing processes and NPI process and production improvement activities.
Such other comparable duties as may be required by the direct superior.

Qualifications

Bachelor Degree or equivalent in Mechanical / Electrical & Electronics Engineering.
Proficiency in spoken and written English and Bahasa Malaysia.
Minimum of 5 years experience in a manufacturing environment.
Good in technical report writing and include complete data analysis and action recommendation.
Experience in new product introduction (NPI), manufacturing activities and documentation (eg: Work Instruction, Control Plan, Process FMEA, Machine and Process Capability Studies, Statistical Process Control – SPC, Time Study (VT), Line Balancing, Setup Plan) is required.
Knowledge of ISO 9001 Standard, TS16949, IEC/EN60745, 62841, Product safety requirement e.g.UL, CSA is an added advantage.
Literacy in Microsoft Office applications.
Familiar with statistical process control methods, MTM-UAS, FMEA and AUTOCAD.
Able to understand and interpret technical drawing.
Hand on experience on failure analysis and problem solving methodology e.g. 5 Why’s, RCA, fault tree analysis etc.
Ability to apply in-depth knowledge of problem solving technique in solving Quality issues including risk assessment evaluation. Effective communication skills with all levels within the organization, suppliers and customers.
Proficient in application of DOE, SPC, MSA, FMEA, MTM-UAS and 8D.
Ability to manage personnel time to ensure completion of assignments. Ability to work with minimum supervision and self-motivation.
Only Malaysian citizens are eligible to apply for this position.

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