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Manufacturing Engineer (Laser Weld) At Magna Powertrain

Location: Unionville, Ontario

Job Description

Company Introduction
This position is for Pullmatic Mfg., a division of Magna Powertrain. Transforming mobility. Making automotive technology that's smarter, cleaner, safer and lighter. That's what we're passionate about at Magna Powertrain, and we do it by creating world-class powertrain systems. We are a premier supplier for the global automotive industry with full capabilities in design, development, testing and manufacturing of complete powertrain systems, including engine and transmission components. Our name stands for quality, environmental consciousness, and safety. Innovation is what drives us and we drive innovation. Find what drives you, and transform your career at Magna Powertrain.
Job Introduction
• Plant expert for Laser Welding manufacturing process
  • Design & Implementation of complete laser welding & associated assembly processes, equipment sourcing, buy offs & production signoff & execution of flawless launch on assigned new programs
  • Lead improvements of current laser welding & assembly processes; cycle time, cost reduction, process capability, FTQ & optimization to improve OEE & program profitability.
  • Resolve production issues related to laser welding processes
  • Assist in the cycle time estimates and quote preparation of laser welded assemblies for customer RFQ’s
  • Support engineering & maintenance activities on assigned work centers & programs
  • Lead & support MAFACT (Lean Manufacturing) activities on assigned process centers
  • Completes project-type assignments of various complexity as required
Major Responsibilities
• Design & present detailed process & build up plan for laser welding assemblies for new programs that is highly optimized (layout, operators, process & material flow, cycle times) and able to meet & exceed customer TAKT time; manage the program from cradle to grave
  • Collaborate with product development engineers in the design & development of laser welded assemblies
  • Create MPP (manufacturing process plan) for new program RFQ’s from customers
  • Quote all new Laser welding related equipment & process costs for new programs
  • Lead & execute process from quotation phase to equipment installation for new programs and/or change to existing programs as a result of engineering changes
  • Develop prototypes for new parts & programs as required. Work with OEM to set up process parameters & successful testing.
  • Create in process drawings for new parts & update current production parts, as required
  • Contribute to concept development, Process FMEA/risk analysis of an improvement/retrofit on existing equipment
  • Present recommendation summary of all relevant details to team members for input and Manufacturing Engineering Manager for final approval
  • Lead and/or participate in CFT meetings to prepare APQP documents; PFMEA, control plans, capability studies, DOE’s, poka-yoke/error proof plans
  • Conduct equipment design review with supplier(s) & coordinates CFT involvement through department managers
  • Effectively manage equipment suppliers and monitor progress through quotation, design, build and installation stages of all new equipment necessary for new programs & improvements/retrofits on current processes/equipment
  • Coordinate all equipment sample runs at supplier & in house and ensure a successful run at rate milestone with customer. Use standard Design Review & Sign Off Checklist to record open issues & follow up.
  • Utilize APQP process to ensure experience and expertise of cross functional team members to deliver a production process that meets all cost, quality, reliability & productivity requirements
  • Evaluate equipment trial runs/buy offs for new equipment & retrofits and ensure run and rate & essential safety regulations are met per OHSA, CSA standards
  • Manage a detailed open issues list with target dates for regular review with the manager
  • Work with maintenance to determine PM schedules on equipment & provide cross training as required
  • Lead for all laser welding & assembly related fast response items, provide weekly updates & target closure within a month
  • Establish machine process parameters for all new programs on Laser welding/assembly processes & continuously monitor to improve/optimize
  • Provide & implement cost reduction ideas on assigned program and use standard trial sheets to record trials.
  • Prepare operator instructions for equipment, update & provide training, as required as well as standardized work instructions, balance charts, JES & combination tables and update as required.
  • Review cell process flow and set up highly optimized machine layout, packaging layout, material flow, process center equipment i.e. inspection tables, chip bins etc. Execute machine & equipment moves to optimize labor & floor space.
  • Complete hand over of machines and process to production and maintenance departments within three months of SOP
  • Use the CN system to enter process change request and ensure timely closure
  • Review employee driven CI suggestions and provide timely feedback and implement approved suggestions.
  • Review health & safety audit items and complete tasks as assigned
  • Complete tasks assigned through GATE reviews on new programs
  • Manage open issues lists and optimization of key processes through KMI.
  • Conduct periodic review of PFMEA and reductions of RPN numbers to improve quality. Complete tasks as assigned to reduce high RPN items.
  • Other duties as required
Knowledge and Education
• Mechanical/Welding Engineering degree from a recognized university or equivalent experience in Laser welding process development & improvement
  • Intermediate to expert level ability to read & interpret blue prints & drawings
  • Intermediate to expert level GDT knowledge & application experience in reviewing stack ups & assembly of various components in an assembly
  • Must have valid P Eng. designation and be in good standing, or must be registered with the PEO as a EIT (applicant in training)

Work Experience
• 5-10 years of Manufacturing/Process Engineering experience managing/improving Laser Welding equipment & associated processes/equipment; such as pressing, washing, balancing, vision systems, robotic material handling cells
Skills and Competencies
• Sound understanding of Laser welding, automation, robotic material handling & metal joining technology
  • Experience in troubleshooting laser welding issues related to laser optics, process capability, quality, scrap, equipment & tooling
  • Lead, participate & provide potential solutions in problem solving techniques such as 8D’s, as required and provide input to root cause and appropriate fix. Close out and present the 8D after solution is implemented and certified
  • Develop, teach & maintain Precitec weld monitoring system
  • Able to use inspection equipment, micrometer, Vernier caliper, gauges
  • Able to review weld cut & etch samples & change/adjust welding parameters as required
  • Able to interpret CMM/inspection reports to provide feedback and make adjustments to the process as required
  • Exposure to CO2 (Rofin Sinar Coherent) Laser welding preferred
  • Project Management and APQP experience
  • Competent decision making, problem solving and analytical skills
  • Excellent documentation, organizational and time management skills
  • Expert in 3D CAD Modelling (solid works), computer skills and drafting experience (AutoCAD, Microsoft Office, Outlook)
  • Excellent English language & communication skills (both verbal and written)
  • Knowledge of IATF16949 and ISO14001 systems
  • Basic understanding of WHMIS, IMDS, Ergonomics, Healthy & Safety regulations
  • Able to work under extreme demands & tight schedules
Work Environment
• Coordination required with CFT
  • Some travel outside of Canada may be required for supplier visits, trade shows
  • Plant environment
  • Work irregular hours and overtime as required by customer demands
  • May include operation of the equipment to assist in the optimization & start up stage
Additional Information
• Comply with legislative requirements including but not limited to Section 28 of the Occupational Health & Safety Act
  • Use or wear equipment, protective devices or clothing that Pullmatic Mfg. requires to be used or worn
  • Report hazards to your supervisor/manager that you are aware of
  • Will not operate anything or work in a manner that may cause danger
  • Ensure TS16949 & ISO 14001 compliance
  • Awareness of all relevant Customer Requirements pertaining to your job function
  • Treat your fellow workers as you would like to be treated
  • Follow guidelines, systems & rules as set out by your employee handbook & company policies
  • Keep your workplace clean & tidy at all times