Process Engineering defines and works out how the product will be manufactured and/or assembled on the production line including design of packaging, ensuring the right quantity of components/products are delivered and aligned to support the speed of the production line. Review efficiencies and eliminate waste within the manufacturing process to deliver high quality products/components to clearly defined standards.Responsible for implementation of production processes and procedures, leading productivity improvements with project based activities, including new product introduction and manufacturing cell design to reduce waste, improve quality and safety, and reduce operating costs. Manage KPIs and ensure preventative actions are taken to maximize success. Work on many phases or sub-tasks of projects or entire projects of moderate complexity, with results impacting on project completion. Work under general supervision, reviewed at project milestones and/or on completion by Senior Management.

Roles and Responsibilities of Process & Manufacturing Engineering

My Skill sets are, Team Management, Team Leading, Project Management, Project Engineering, Project Coordination, Production Engineering, Process Engineering, Process Simulation, Process Design, Bom Preparation, Die Casting Design, Pro-E, Press Tool Design, Mould Design, Plastic Product Design, Injection Mould Design, Design Engineering, Project Engineering Management, HPDC Tooling Designing and Manufacturing, CNC Programming, Tooling’s, TPM, Lean Manufacturing, SMED, Value Stream Mapping, TPM Methodology, Kaizen,During the Projects, the Following Activities are Inspired me every moments, A Good Communicator, Integrity, Enthusiasm, Empathy, Competence, Ability To Delegate Tasks, Cool Under Pressure, Team-Building Skills, Problem Solving Skills.Developed a solid business case of the Project, Where appropriate research points out & developing a business case and identified the Keys. Ensure the project fits with the key organizational or departmental agenda. Carry out risk analysis at a high level at the initiation stage. Identify the key stakeholders & consider the Matrix need to consult or involve them at the business case stage.

1. Introduction: What is P.E. & M.E.?

2. System Integration: Necessary & Difficult

3. Int’l Comparison of System Integration

= Key role played by P.E. & M.E.

= Key role played by development

(i.e., product engineering)

4. Overseas expansion of Companies: Doing the

style of P.E. & M.E. Processes?

Agenda:

What is P.E & M.E.?

– Set plant layout & production process flow – Establish standard operating procedures – Design production equipment

1. Manufacturing Engineering sits between

product development and manufacturing in

the value chain

2. Roles of P.E & M.E.

Definition: To develop, implement, monitor and maintain efficient manufacturing processes and workflow, for assembly products (PFMA).Key Responsibilities:

General and Task Management • Identify manufacturing needs for new products in development• Design new systems and processes and provide facilities & methods to ensure the

cost effective integration of new products or for the improvement of existing ones into manufacturing operations

• Ensure all product and system requirements are taken into account from the initial product conception to the finished result Assist with shop floor layout and cell designs

• Design fixtures and tooling for assembly tasks• Generating production documentation such as assembly instructions• Reduce variability in manufacturing by providing standard work methods• and work instructions Ensure product and process quality meets specifications

required• Support the tender process for equipment to ensure the best quality for best price• Oversee installation of machinery and equipment

• Maintain statistical and financial records & Improve manufacturing efficiency by analyzing and planning work flow,

• space requirements and equipment layout, remove waste from the processes• Organize plant start-up and shut-down schedules to ensure minimum loss of

production time • Plan and organize maintenance, respond to breakdowns & report down time and

possible trends• Support and lead continuous improvement, problem solving and process

improvement activities • Carry out FMEAs, (Failure Mode Effects Analysis) process documentation and

implement improvements• Poka Yoke (error proofing) where possible to prevent errors• Investigate production and process issues providing technical support and• training Keep up with current and developing engineering trends• Undertake special projects as required• Contribute to continuous improvement activities• Quality control of work by appropriate reviews• Support and lead process improvement activities• Write reports and present progress at project meetings and to clients

• Achieve goals within budget & conduct benchmarking studies to determine best practices/designs and

• future trends Plan projects or subtasks so they may be tracked and presented

• Manage the Key Performance Indicators (KPIs)• Attend various meetings and action/communicate

instructions• Produce written reports and make presentations• Undertake continuous training and development, perform

root cause analysis and resolve problems• Lead and/or support technicians and trainee engineers• Train people within own work group and Supervise sub-

contractors• Liaise and communicate with other departments, customers,

suppliers and other service providers

Self Management:• Comply with the Health, Safety and Environmental Policies• Assertive, resilient and welcomes change• Engages interest and participation of others and has a

collaborative• approach to working together Actively committed to teams

development• Is optimistic and self aware, shows moral courage,

openness and honesty in all dealings• Self-motivated, flexible, proactive and committed, good

communication and interpersonal skills

Skills and Attributes: • Independently determines approach and assigned tasks along with understanding

the manufacturing processes• Understanding engineering, scientific and other technical information, strong

problem-solving skills and logical approach• Understand lean manufacturing and ability to work in a diverse and dynamic

environment• Planning and prioritizing activities, Excellent negotiation skills and ability to present

data effectively• Understanding of Health and Safety practices, Team working skills, Analytical skills

and PC skills• Exercises latitude and technical judgment in deciding work methods• Ability to train the work group and lead teams within the work group• Ability to manage group to achieve goals within budget• Good understanding of customer expectations & deliverables with an awareness of

the impact of failure/cost of poor quality• Professional accreditation with an industry related body would be advantageous• Ability to use CAD & Ability to design processes and layouts• Experience of FMEA (Failure Mode Effects Analysis), Kaizen/A3 (continuous

improvement and problem solving)process improvement and Poka Yoke (error proofing) techniques

• Significant work experience in a high volume manufacturing environment, preferably automotive

• Experienced with a number of systems, expert in at least one area and working knowledge of a number of other areas of specialization

• Understanding of design and production costs to include waste, downtime, scrap and re-work

• Organize, implement and maintain production process flow• Develop working instructions, workmanship standards and process

documents, and ensure they are followed• Improve continually existing operation, for increased quality, productivity,

efficiency and cost savings • Investigate operational problems affecting production and reporting and

recommending solutions • Liaise with production planner/scheduler for ensuring the released

products have adequate BOM and routings • Manage manufacturing documentation required for product manufacturing

i.e. revise drawing, BOM, accurate work instructions and workmanship standards and process procedures

• Provide manufacturing data i.e. production control charts, reliability, process capability, to improve the process and monitor and measure progress to target

• Organize meetings with other team members to facilitate growth • Identify ways to reduce production costs through recommendations – i.e.

new process equipment, equipment justification to improve performance

• Work with design engineering on DFX (design for excellence) to include: o Design for cost o Design for test o Design for manufacturability o Design for assembly

• Work with other relevant departments to determine estimated costs, run time, cost reduction and close the feedback loop

• Liaise with suppliers on manufacturing process • Train and supervise staff on new development processes and technology • Establish a training and quality culture• Confidently monitoring of all cell custom build, lean Manufacturing, six

sigma and ISO methodology• Proven track record and working knowledge for manufacturing process • Responsible for Plant layout and Modification in Existing Plant Layout,

Fully responsible for new Plant Infrastructure and value stream Mapping.

Process & Manufacturing Engineering

System Integration Example

Integration is often Difficult • Integration is made difficult by:

– Uncertainty in user needs – Trade-offs among a product’s functions – High complexity of structural component interactions

• Automakers faced with great challenges in all three of these areas

Difficult System Integration

Examples…

• Piston and Piston Ring • Car Door • Car

Piston and Piston Ring

Car Door

Car

System Integration in Automotive Product Development

• Integrate movement of information • Maximize the time spent on value adding activities • Two Types of Integration

– External integration (achieving fit w/ customer needs) – Internal integration (coordinating divisions & suppliers)

• Key complicating issues : Uncertainty in… – User needs, user interface – Product’s structural interactions – Product’s functional interactions

• Principal system integrator (the lynchpin): HWPM (Heavy-Weight Product Manager)

Integrative Role of HWPM

• Heavy-Weight Product Manager (HWPM) is the cornerstone of lean development for products:

– With high complexity, and – Equivocal user needs

• HWPM leads both external and internal system integration (i.e, plays the role of both a planner and an engineer)

Automotive Lean Manufacturing • Whole plant optimization to minimize waste

– Integrating the movement of… Material Work Activity Information …to get smooth flow from input to output.

• Key complicating issues: Uncertainty in… – Market demand – Manufacturability of product design – Parts/component delivery

• Principal system integrator (the lynchpin):

P.E. & M.E.