About The Role

STA Site Engineer is responsible for supplier part quality launch and capacity. Key responsible for supplier development.

Responsibilities / Accountabilities

Drive Flawless Launches at assigned supplier sites, collaborating with Launch STA team (Ex: Schedule A, PPAP (Production Part Approval Process), Supplier Quality Issues resolution). Escalate significant issues promptly and ‘date to green’ plan to appropriate management
Conduct onsite evaluation visits for Priority commodities as per GPDS supplier engagement process for new programs
Review supplier incremental tooling work plans compliance to PPAP (Production Part Approval Process) requirements
Drive robust Supplier Failure Mode Avoidance through PFMEA, SCCAF, CP reviews, Manufacturing feasibility reviews and Health chart deployment as applicable
LEAN principles expertise (Bill of Design / Bill of Process / Bill of Materials)
Drive Supplier manufacturing health chart compliance and support development of new health charts
Drive suppliers for Special process compliance with the support of STA Technical Specialists and Industrialization Reviews
Support Capacity Purchase team in capacity studies interfacing with suppliers and Ford cross-functional teams
Drive capacity/uplift actions implementation with suppliers inline with the GCP study requirements
Drive Supplier Process capacity issues resolution as needed – Production constraint risk mitigation working with Ford and Supplier teams and manage “date to green” plan
Monitor supply status of 24/7 roster suppliers and Blue bar status of PPAPs beyond implementation timing
Review supplier Capacity Analysis Reports (CAR) for compliance to capacity requirements
Drive continuous improvement in manufacturing excellence with the assigned sites through Q1-MSA deployment, Q1 attainment/ retention, Health chart deployment, Supplier training as required.
Drive deployment & improvement of Quality performance requirements (Q1, QR, TGW, R/1000, CPU), through Warranty Reduction, Benchmarking, Lean Manufacturing, G8D (Global 8 Disciplines) methodology, PFMEA (Process Failure Mode Effect Analysis), SPC (Statistical Process Control), Gage R&R (Repeatability and Reproducibility), Gage R&R (Repeatability and Reproducibility), etc.) as required
Drive new supplier site evaluations and Supplier Risk Assessment on new sourcing in support of GCST, identifying Risk Mitigation.
Drive closure of supplier process responsible quality issues related to Stop Ship/Build, BSAQ (Balanced Single Agenda for Quality) projects and Field Action Stop Ship/Prevent Action
Drive compliance to all organizational and corporate training requirements and SIM process compliance.

KNOWLEDGE, SKILLS and ABILITIES (KSA)

Good communication and listening skills
Self-starter and team player
Attention to detail
Be able to work under pressure and to multitask
Proficient in English language
MS Excel, MS PowerPoint skills & experience

QUALIFICATIONS and EXPERIENCE

Qualification: B Tech Mechanical or Industrial Engineering or academic equivalent.
10 - 15 years of relevant experience in motor Industry
In depth process & technical experience in Sheet Metal Stampings, Assy Welding Process commodities, process controls and typical error states
Know how in Die/Tooling/Weld Fixtures will be an advantage
Knowledge in Locator Principle, GD&T, Blue light or part Scan techniques [min interpretation of results],
Know-How in PCF exercise to coordinate panels
Relevant work experience in LEAN Principles
Knowledge of Problem Solving and Quality systems and tools
Experience in Quality systems, tools and techniques
Project management experience
Supply / Crisis Management Experience
Knowledge & Experience in manufacturing process(es) viz., Stampings and Modular assembly