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Senior Process Improvement Engineer (Paint)

Louisville, KY, United States  |  Engineering  |  ID: REQ-9882

Description

Job Location

USA, Louisville, KY

Job Posting Title

Senior Process Improvement Engineer (Paint)

The Challenge

Manages equipment and process effectiveness within a production area. Troubleshoots process issues and drives operational improvements, through effective problem solving and corrective action implementation, to continuously improve safety, quality, delivery, cost & morale.

What you will Do

Responsibilities:

  • Ensure powder coating processes are maintained and running effectively for production.

  • Problem-solve (analyze data, determine root causes, develop implementation plans) and resolve issues that are affecting powder coating quality or throughput.

  • Support implementation of new processes & equipment.

  • Proactively identify & pursue opportunities to improve operations by reducing cost, reducing energy usage, improve quality, etc.

  • Drive safety of the shop and of operators.

  • Interface with production/maintenance associates, plant leadership, and others outside of the plant (Manufacturing Engineering, suppliers, etc.) as needed to resolve issues, implement improvements, and communicate status & opportunities, etc.

  • Proposes and evaluates the processes for equipment in the assigned area.

  • Provides technical support for specific plant operations.

  • Coordinates input from internal/external customers to better understand customer needs and/or perceptions.

  • Keeps abreast of current product developments and trends in areas of expertise.

  • Actively identifies new areas for learning and takes advantage of learning opportunities.

EQUIPMENT:

  • Own all equipment and tooling in the production area, from Advanced Mfg Engineer (AME) sign-off and forward.

  • Serve as the primary troubleshooting resource for the process in the plant. Consult with maintenance staff on equipment repair.

  • Monitor and work to improve Overall Equipment Efficiency (OEE) in the area.

  • Recommend equipment and tooling for the existing process; consult and sign-off on new purchases when applicable.

  • Consult with Maintenance Business Leader on the maintenance action item list and/or priorities for the area.

  • Monitor and ensure the calibration of all equipment.

  • Provide feedback on equipment specifications (Gray Book content) based upon best practices and lessons learned.

  • Partner with plant TPM and AME teams to implement and maintain a robust TPM plan for all equipment.

CONTROLS ENGINEERING:

  • Improve and direct Preventive Maintenance plan for assigned area.

  • Root cause-based troubleshooting, schematic reading, PLC's and ladder logic programming, variable frequency drives, Ethernet communications, Vision Systems, and safety procedures such as Lock Out -Tag Out.

  • Support all plant priorities in the areas of EHS, Schedule Attainment, Spoilage & Yield, Labor & Overtime, Productivity, Spare Parts cost controls, and Lean Manufacturing.

  • Execute routine equipment purchases, including presenting justification for capital expenses or process improvements, design, and specification of equipment, and standardization of equipment within manufacturing methods and safety requirements.

  • Provide training and aid in troubleshooting and downtime response in the specified area of expertise.

  • Steer up-time and equipment reliability improvements through simplification activities.

  • Develop and guide cross-functional projects with other departments and suppliers to make the entire supply chain more robust, driving OEE.

CONTINUOUS IMPROVEMENT:

  • Engage in and lead problem-solving for the production area. Lead root cause identification of problems, implement appropriate countermeasures, and share across as best practice (yokoten).

  • Partner with Plant Operations personnel to promote and support a team that reacts aggressively to factory inefficiencies. 

  • Work cross-functionally with Team Leaders, Kaizen Promotion Officers, Business Leaders, and Lean resources on short-term and long-term improvement initiatives. 

  • Implement related countermeasures on manufacturing line(s) (kaizen activities). 

  • Implement Poka-Yoke work methods, and develop workstation aids to assist in operator job performance. 

  • Support the Team and Business Leaders in the planning and execution of work area rebalancing utilizing Yamazumi charts. 

SAFETY:

  • Support Business Leader by identifying and implementing safety-related corrective actions and improvements for the area. 

  • Assist with action item completion for the area's safety action item list, including corrective actions from near misses, accident reports & ergo assessments.

NPI LAUNCHES:

  • Coordinate with AME on equipment purchases & qualification. 

  • Provide the "voice of the plant", giving feedback on lessons learned and plant preferences. 

  • Review product prototypes and concepts for manufacturability. 

  • Provide feedback to the NPI team on capacity, impact on operator, and process stability/sustainability. 

  • Interface with vendors and OEM suppliers, along with Facilities Engineer, to learn maintenance requirements and equipment troubleshooting. Distribute information and knowledge. 

  • Update manufacturing control documents, floor & workstation layouts. Work with Team Leaders on Standard Work and Job Instruction creation.

What you need to Succeed

Position Requirements:

  • Demonstrated experience in troubleshooting high volume manufacturing equipment

  • Strong project management and analytical/problem solving skills with demonstrated ability to scope and analyze cross-functional problems to generate/implement solutions

  • Ability to adapt to and juggle changing and competing priorities

  • Early and/or late hours often required to work around the manufacturing schedule / timing

  • Ability to work collaboratively in a cross-functional team environment with both hourly and salary personnel to meet the needs of operators, the program and the business

Minimum Qualifications:

  • Minimum of Bachelor’s Degree with technical degree required

  • Minimum of 5 years’ relevant work experience

  • 5 plus years of experience in powder coating and surface preparation of components prior to powder coating.

  • Knowledge of paint/coating system controls, delivery systems, and quality control monitoring systems associated with painting/coating processes

  • Leadership experience in manufacturing operations, preferably unionized operations

Preferred Qualifications:

  • Knowledge of Appliances manufacturing processes.

  • Experience in Controls, PMs, mechanical, hydraulic, pneumatics and welding techniques

  • Experience and training in lean manufacturing practices

  • Six Sigma Black Belt certification

  • Quality Leadership experience

  • Program Management skills

GE Appliances is an Equal Opportunity Employer.  Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.

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