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Role Summary: The Manufacturing Engineer is responsible for leading industrialization activities. She/He must take full responsibility on the assigned hardware and will develop the manufacturing process to achieve the required targets in terms of process robustness, product quality, product cost, capacity sustainment.
Develop the manufacturing processes for gears, including the design of the manufacturing sequence, operation sheets and work instructions, the definition of fixtures, tooling, the design of the machining phases and parameters in cooperation with the NC programmers, the selection of the appropriate machines and equipment, the definition of the inspection methods and applicable gauges
Collaborate in the New Product Introduction by implementing the new manufacturing process in order to match the prototypes deliveries, achieve the quality and cost standard according to the planned learning curve
Cooperate with the special processes specialists in the definition of the appropriate heat treatments and any additional special process required by the drawing
Support the shop activities in the development phase of the process, by training the operators on the correct interpretation of the work instruction and tuning the process
Get input from the Business in terms of a problem involving inadequate values of FTY, WIP, cost, lead time or machinery saturation of a stated product or product family
Follow the steps of a six sigma approach in order to define a solution to the aforementioned problem. The solution must be defined with a team involving at least a senior manufacturing engineer or the manufacturing engineering manager, but generally also the shop, engineering and quality representatives
Carry on all the data gathering and the analysis required for the definition of the problem and the identification of the solution
Develop the modified manufacturing processes allowing for the solution of the problem, by introducing the modified process, i.e. carry on the machinery acquisition process, carry on the fixture modification or acquisition process, carry on the tooling selection and acquisition process, cooperate with the programming team for the development of the required software (part programs), modify the router in the AvioAero PDM system, manage the validation process
Control – through the periodical update of proper KPIs – that the problem is solved and that is solved in a stable manner
Define investment and expenses needs to achieve target plant metrics. She/He will drive the whole project from business plan preparation to approval, order placement, material acquisition and validation of the newly defined processes
Bring new ideas and positive support to the current process
Interface with vendors and internal contacts in an effective manner to ensure that the technical perspective is properly conveyed
Ensure that all engineering designs and technical data are complete and accurately documented to provide an accurate technical/historical base for future reference and to meet customer/end user requirements
Bachelor's degree or Master Degree in Mechanical, Aeronautical or Industrial Engineering
Significant experience in manufacturing of gears
Good knowledge of the metal cutting technologies, machines tools, types & materials of cutting tools involved in gears manufacturing and about the most important applicable special processes
Good knowledge of process design: process sequence, material removal strategy, clamping and centering, tolerance chain and stack-up, MCT
Ability to read engineering drawings and specifications
Knowledge about NC machines and CAD/CAM tools
Knowledge about metrology principles and characterization of surfaces, shapes and dimensions
Ability to analyze problems, identify root causes and provide efficient solutions
Ability to handle diverse activities simultaneously
Strong organizational skills
Ability to work in a matrix organization
English and Italian fluent
EU work permit
Prior experience with Lean Manufacturing
Prior experience with Six Sigma
Strong interpersonal and leadership skills
Strong oral and written communication skills
Ability to communicate effectively and contribute to team projects Interface Customers for major issues.
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