Engineer - Process (Fixing Value Stream)

Company Description Bosch has been present in Malaysia since 1923, represented by Robert Bosch Sdn Bhd, with offices located in Selangor and Penang. In Malaysia, Bosch has diversified businesses in Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The company has three manufacturing plants in Penang providing Car Multimedia, Power Tools and Automotive Steering systems. In 2017, Malaysia contributed sales of RM 615 million (127 million euro) and employed more than 2,800 associates. Job Description • Responsible for new product line setup and release. • Plan for MAE and EWAK investments related to workstation and accessories for new and existing lines. • Define, purchase, set up, perform trial run and buy off for all workstations and accessories of new products. • Prepare workstations layout, set up workstation, prepare line release documents and perform manufacturing line buy off before Pilot Run or mass production. • Perform Machine and Process Capability Study to ensure machines and processes meet the capability requirement during mass production. Identify and introduce SPC on certain processes whenever applicable. • Train and guide trainers, supervisors and maintenance personnel by transferring technical and process know-how. • Monitor and supervise VSE technician performance to ensure efficiency in value stream improvement activities and processes. • Responsible for process improvement project in production through time study - VT improvement, direct productivity improvement, ergonomic, workstation, machine and technology improvement and update Management on the improvement result. • Support production in achieving the effectiveness, output, FOR and quality target through continuous improvement activity. • Liaise with maintenance personnel for maintenance plan set up and spare parts replacement for existing machine used in production. • Involve in failure analysis of production FOR and advise failure analyzer on the disposition of the rejected parts. • Involve in Sales Driven Activity (SDA) projects and prepare supplement line release documents for mass production. • Provide support for Quality problem resolution through problem solving skills PSS or 8D. • Monitor, report of KPI’s in timely manner and establish action plan. • Optimizing equipment and processes to maximize output & quality and minimize cost. New Product Introduction • Responsibility for Start up projects, workstation layout, MAE, EWAK investments, new product line setup, workstation buyoff and release, etc. • Prepare Supplier Requirements Specification (SRS) for purchases of new machines and/or fixtures. • Actively involves in Product and Process FMEA, prepare Control Plan and production line release documents before mass production. • Coordinate PGL Guidelines workshop with PGL coordinators and project team members. • Prepare VT calculation and line capacity planning based on the projected volume for PHEK calculation. • Perform machine and process capability studies to ensure machine and processes meet the capability requirement before mass production. • Coordinate sample build in project, prepare pre-pilot and pilot run report and ensure close loop of the action implemented. • Provide training to trainers, line leaders, supervisors and maintenance personnel on assembly processes of new products by transferring the technical and process know how. • Prepare line readiness for new product SOP and SDA activity (eg: workstation buy off, line walk, ESD audit) during pre-pilot and pilot build. Operation Support • Responsible for – process improvement activities in production (Time Study - VT improvement, direct productivity improvement, ergonomic, workstation, machine and technology improvement) • Provide assistance to resolve line FOR issues through failure analysis and advise failure analyzer on the disposition. • Support cost saving activities and approve alteration change. • Regular review and update of Production and Quality Instruction (WI), Product Quality Indication (PQI), Control Plan and Process FMEA based on the latest process control in production. • Ensure ANDI contents is checked before release and implemented correctly. • Conduct process confirmation to ensure line and process compliances and cycle time according to approved time study (VT) summary. • Conduct failure investigation with cross-functional team for non conformance incidents (VQ failure, customer complaint, FOR, etc). • Drive cross functional team for core tools projects, direct productivity improvement and continuous improvement activities. • Involve in Sales Driven Activity (SDA) projects and prepare supplement line release documents for mass production. • Active involvement in internal and external audit with updated documentation, production system and line readiness during the audit. • Implementing process improvements and technological upgrades to optimize QCD (quality, cost, delivery) and considering digital data recording for evaluation and traceability. • Evaluates MES data to find bottlenecks in machine efficiency and quality problems. Qualifications • Bachelor Degree or equivalent in Mechanical / Electrical & Electronics Engineering • Proficiency in spoken and written English and Bahasa Malaysia. Understand mandarin will be preferred. • Minimum of 3 years experience in a manufacturing environment. • Good in technical report writing and include complete data analysis and action recommendation. • Experience in new product introduction (NPI), manufacturing activities and documentation (eg: Work Instruction, Control Plan, Process FMEA, Machine and Process Capability Studies, Statistical Process Control – SPC, Time Study (VT), Line Balancing, Setup Plan) is required. • Knowledge of ISO 9001 Standard, TS16949, IEC/EN60745, 62841, Product safety requirement e.g.UL, CSA is an added advantage. • Literacy in Microsoft Office applications. • Familiar with statistical process control methods, MTM-UAS, FMEA and AUTOCAD. • Able to understand and interpret technical drawing. • Hand on experience on failure analysis and problem solving methodology e.g. 5 Why’s, RCA, fault tree analysis etc. • Ability to apply in-depth knowledge of problem solving technique in solving Quality issues including risk assessment evaluation. • Effective communication skills with all levels within the organization, suppliers and customers. • Proficient in application of DOE, SPC, MSA, FMEA, MTM-UAS and 8D. • Ability to manage personnel time to ensure completion of assignments. • Ability to work with minimum supervision and self-motivation. • Applicants must be Malaysian citizens.