Title:  Senior Engineer, Forming

Job Summary

In this role, the incumbent is responsible to support overall vision of Manager, Production, in optimizing and improving the production workflows or processes involved in systems, procedures, and training, to ensure the aspects meet present and future requirements for Safety, Quality, Delivery, and Cost improvement. Responsible to lead the Business Support team in providing administrative support to Production Managers and Supervisors, to achieve high efficiency in production operations.

This role will support a team of Production Training Leads, to manage the Training Within Industry (TWI) program within production departments, to build up the competency of production workforce. This role is also responsible for assisting Production Managers in facilitating the Material Review Board (MRB) processes, to streamline the disposition of non-conforming materials, and reduce scraps and rework where possible. This role shall assist Manager, Production in driving for Operational Excellence (OPEX), execute activities specified in OPEX roadmap, to achieve target maturity level under West Business System (WBS).

Essential Duties and Responsibilities

• The employee is informed of all relevant SOIs / WIs that are an integral part of the Quality Policy, and which are related to the job covered by this job description.
• Work with formal systems, such as cGMP, ISO, to ensure that existing processes and workflows within production are in conformance with Safety and Quality requirements. Ensure that change control procedure is strictly followed.
• Lead in investigating open Deviations and Out-of-Specification (OOS) events to ensure their timely and effective resolution and support the implementation of CAPAs to prevent recurrence. 
• Initiate, coordinate, and implement improvements of existing processes or workflows in production by following a systematic approach, ensuring it meets the requirements of Safety, Quality, Delivery, and Cost (SQDC)
• Lead the use of problem-solving tools (e.g., A3) and techniques in everyday problem solving and process improvement activities, include provide coaching to team members when required.
• Coordinate with partner sites within Advanced Manufacturing Value Stream (AMVS), to explore best practices in production processes and workflows, adopt and implement where feasible.
• Lead the business support team to support Production departments in purchasing activities through approved vendors, include handling of Request for Quotation (RFQ), Purchase Request (PR), Delivery Orders (DO), Invoices, etc.
• Ensure all production records/documents are adequately filled by the business support team, as specified within existing procedure. Support audit activities by retrieving filled records/documents, as and when required by Quality department.
• Lead the business support team to provide administrative supports to Production departments in managing production data and reports, include updating production trackers, reports, KPI boards, etc.
• Manage the inventory of Personal Protective Equipment (PPE) for production departments, ensuring there are sufficient supplies to production personnel.
• Responsible for the management of production gowns and staff lockers for production departments.
• Drive for implementation of Training Within Industry (TWI) program within production departments, following the established roadmap.
• Collaborate with Global project team of TWI implementation, continually assess and review site TWI program, ensuring it is aligned with the Global direction, under the standardization approach.
• Conduct Train-the-Trainer session for TWI - Job Instruction (JI) method to newly assigned Production Training Leads or Production Trainers.
• Responsible for performance management of Production Training Leads, including provide coaching/mentoring, conduct performance appraisals, and establish development plans.
• Lead the daily Material Review Board (MRB) process, to collectively determine disposition of non-conforming materials promptly and reduce scrap and rework where possible.
• Manage the rework activities of QC rejected Semi-finished Goods (SFG), to prevent it from contributing to delivery OTIF failure.
• Lead the production team for annual stock count activities, include pre-stock count preparation, resources planning, establishing workflow, and provide training to the involved personnel.
• Continually analyze, evaluate, and review existing Work-in-Progress (WIP) and inventory management methods, identify the gaps, and initiate for improvement by utilizing Lean Six Sigma methodologies.
• Assist in driving for Operational Excellence (OPEX) in production department, execute or participate in tasks as assigned by superiors to achieve target maturity level.
• Ad-hoc duties as assigned by superiors.

Education

• Bachelor’s degree in engineering or equivalent.
• Minimum 5 years of experience in a manufacturing environment.
• Experience in elastomer manufacturing or elastomer related manufacturing is preferred.
• Experience working with ISO9000, and cGMP is preferred.

Preferred Knowledge, Skills and Abilities

• Knowledge of LEAN and 6 Sigma manufacturing principles.
• Knowledge of ISO 45001/local HSE legislation, manufacturing, and process automation.
• Proficiency working with computers and various applications- i.e., SAP, MES, and Microsoft Office applications.
• Effective problem-solving by utilizing problem-solving tool, i.e., A3.
• Strong interpersonal skills.  Ability to establish and maintain good working relationships with all levels in the organization.
• Able to be aware of all relevant SOPs as per Company policy as they are related to the position covered by this Job Description
• Able to comply with the company’s safety policy at all times and all local environmental, health & safety regulations.
• Ability to work in fast pace while remain high attention to detail.
• Ability to take responsibility for successfully performing given tasks.
• Ability to work as a team in activities to achieve business goals.
• Ability to provide feedback, guidance, and coaching to help others excel in performing their tasks at work.
• Ability to read and interpret documents and specifications, safety rules, operating instructions, procedure manuals and regulatory documentation.

Additional Requirements

• Comfortable working in a cleanroom manufacturing environment.
• Specific vision abilities may be needed by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus.
• Must follow and comply with Plant’s Dress and Hygiene Code (SOI).
• Must be able to tolerate heat and industrial odors/smells on a frequent basis.
• Must be able to multi-task, work under time constraints, problem solve, and prioritize.
• Must also be able to maintain confidentiality and resolve conflicts.
• Ability to make independent and sound judgments.
• Travel <10%.