Process Development Engineer

• Lead the implementation of complete fabrication process for new programs and ECNs to achieve production and quality signoff and flawless launch as per internal and customer timing/deadlines/milestones standards and requirements.
• Review/analyze component/assembly drawings, participate in internal PFD review meetings and provide subject matter expertise/input to produce the part repeatably as per internal and customer standards and requirements while also providing input during quoting phase as required.
• Provide input in tooling design, machine selection & establishment of process parameters.
• Participate in cross functional APQP meetings to provide input in DFM and GDT analysis, PFMEA, control plans, process capability studies, DOE's, poka-yoke, error proof plans, root cause analysis, and lessons learned.
• Coordinate pilot build with prototype development department, document & communicate lessons learned to product/project engineer/process development manager & ensure the lessons learned are effectively carried over to the production process.
• Collaborate with manufacturing engineer responsible for BOM/routing set up after tooling validation & ensure any changes to the process flow are communicated & updated in the system.
• Lead and coordinate all tooling validation sample runs at supplier(s) and at ADG to ensure a successful run at rate milestone completion based on TAKT time, internal AQPQ and customer PPAP requirements and standards.
• Capable of reading and evaluating CMM reports, quality inspection data, capability reports to provide feedback on process (tooling, equipment) changes required to achieve product capability as per internal and customer standards.
• Provide input in evaluating equipment trial runs and buy offs for new equipment and retrofits and ensure run and rate, PPH and essential safety regulations are met per ADG, OHSA, ESA and CSA standards.
• Conduct training for associates on new equipment and processes, monitor progress and ensure timely and effective handover to production and maintenance using ADG standard Machine Handover Checklist.
• Establish machine process parameters for all new programs and continuously monitor to improve and optimize.
• Prepare, release, maintain and update standardized work instructions, operator instructions, job element sheets, troubleshooting guide(s) for process & equipment.
• Provide technical expertise to production to resolve fabrication process capability and quality issues.
• Communicate with Maintenance and/or Operation Manager on tooling problems related to production.
• Review daily shift and quality reports for top process issues. Discuss with Operations manager, Production Supervisor, Lead Hand and/or Process Development Manager to resolve the issues.
• Co-ordinates the implementation of ECN’s (Engineering Change Notices), internally or customer driven.
• Lead process and equipment root cause analysis initiatives and implement solutions to improve and sustain OEE to ADG standards.
• Maintain an open issues matrix for assigned projects and tasks and ensure timely completion as agreed with the direct manager.
• Lead and participate in 8D, 5 Why’s, RCA, CI meetings for customer complaints, failures and provide appropriate input to resolve issues.
• Assist in reviewing program profitability and provide ideas to reduce waste in the value chain by effectively utilizing lean manufacturing principles.
• Work closely with Maintenance/Tooling Manager and skill trades team to increase machine uptime, conduct RCA on equipment issues and follow up on closure.
• Support the implementation of best practices for the department and the development, monitoring, and application of KPI’s (productivity, cost, quality, safety).
• Other duties as assigned by Management.

• Mechanical Engineering degree/diploma.
• Lean Six Sigma Black Belt or Green Belt desirable.

• Minimum (10) years of hands-on experience in a metal fabrication environment, preferably automotive.
• Experience with tube bending process a definite asset.
• Proficient in blueprint reading and interpretation, and operation of tool room and production equipment (grinding, milling, lathe etc.).
• Strong leadership and communication skills.
• Team player who thrives in a fast-paced work environment.
• Excellent mathematical and mechanical aptitude.
• Excellent trouble-shooting skills for fixtures, cutting tools and Tool Room machinery.
• Strategic thinker with the ability to advocate new ideas, cost savings.
• Sound understanding of SQC, SPC, GDT methods and techniques.
• Intermediate level knowledge of 3D CAD modeling including Creo and AutoCAD.
• Intermediate level expertise in MS Office packages (Word, Excel, PowerPoint, OneNote).
• Self-motivated and able to work with minimum supervision.
• Able to work under extreme demands and tight schedules.
• Able to accept directions and change directions as required.
• Excellent English language, communication, and presentation skills (both verbal and written).
• Basic understanding of WHMIS, IMDS, Ergonomics, Healthy and Safety regulations.
• Some travel may be required.

• Competitive compensation and vacation packages based on current industry norms.
• Group health benefits.
• RRSP matching.
• Advancement opportunities and lateral movement based on personal interest and qualification.

Active Dynamics