Position Summary
Assumes full technical responsibility for planning, organizing, and executing the fabrication of complex cable assemblies, utilizing injection molding and automated testing. Recommends and implements improvements to current & future injection molding processes, methods, and controls.
DUTIES and RESPONSIBILITIES
- Develops cost-effective injection molding, jig & fixtures, processes, and methods, in accordance with customer specifications and quality standards
- Identify key process indicators (KPIs) and collect data into meaningful metrics on a routine basis. Use basic SPC to monitor performance and suggest areas of improvement
- Create and maintain required documentation for all manufacturing processes, including flow charts, capacity and utilization studies, time and motion studies, standard workflow, cycle time analysis, and line balancing.
- Coordinates interpretation of complex technical designs into clear and understandable assembly instructions for execution by shop floor personnel
- Review customer specifications for Build to Custom Design projects, provide feedback to Project Managers and customers as required
- Design and develop complex manufacturing concepts to simplify and improve processes and ensure best practices. Develops manufacturing cost analysis of cable products and ensures workflows are optimized over time to achieve cost targets.
- Responsible for all activities relating equipment process validations (PPAP), DQ, IQ, OQ, PQ
- Perform PFMEA Risk Analyses when required (ISO 13485 opportunities), develop plans to mitigate risk, and keep PFMEA alive throughout product life
- Define all manufacturing process steps and equipment required for the complete fabrication and qualification of a cable assembly
- Propose and implement corrective measures to address customer complaints using Six Sigma, 8D, and RCCA forms and methods
- Develop and test new DFM methods to support innovation and improvements utilizing lean manufacturing, Kaizen, Six Sigma methodologies
- Assist in the writing and editing of manufacturing procedures and processes to support best practices
- Work with Design Engineering to support injection mold designs for medical, defense and commercial applications.
- Provide leadership, training, and guidance to junior manufacturing associates in the execution of everyday tasks
- Other duties as required
Required Qualifications
- Bachelor’s Degree in engineering preferred (BSME, BSIE), or significant related work experience
- Five (5) years minimum experience in the mold making and injection molding industry.
- Experience with soldering, and crimping technologies including post termination performance and inspection requirements
- Able to understand/interpret customers electrical, mechanical, and quality requirements
- Strong project organization and time management skills
- Excellent verbal and written communication and presentation skills
- Working knowledge and use of 3D CAD such as Inventor or SolidWorks
- Hands-on ability to work with small tools and develop fixtures and mechanical devices as manufacturing aids.
Additional Preferred Qualifications/Skills
- Knowledge of various plastic materials used in the injection molding process such as PEEK, POM, PTFE, FEP, VMQ, Rubber, Polyamide, Polyurethane, PA6.6, PPSU, PSU, etc.
- Knowledge of various platings and coatings such as electrolytic nickel, electroless nickel, nickel hardened gold, and electroless nickel immersion gold (ENIG)
- Knowledge of various adhesives and potting compounds for bonding and electrical isolation and protection
- Familiarity with CFD, Mold Flow software analysis and interpretation for injection molding
- Familiarity with IPC 610/620 standards, ISO 9001, 13485
PHYSICAL JOB DESCRIPTION
Typical Working Conditions:
- Office environment, Quality Laboratory, Engineering Lab, Cable, Connector, injection molding work areas
Equipment Used:
- Computer and office equipment and tools used in Cable Assembly and Connector Assembly departments
- May work on equipment including injection machine, injection molds, CNC machines, Lasers, test equipment, crimp applicators and presses, programmable prep equipment, automated dispensing equipment, etc.
Essential Physical Tasks:
- Sitting and/or standing for prolonged periods of time
- Able to lift 25 lbs. on occasion.