Corporate Process/Quality Engineer – Lafayette, IN (Posted 4/15/13)
Monitors, identifies and drives projects in the production facilities focused to process and quality within the facilities and at customer locations. Develops and supports training of internal resources on best practice processes as well as customer applications. Supports the development of a highly motivated plant organization capable of achieving corporate goals and objectives.
Duties and Responsibilities
1. Develops and maintains listing of internal and applicable external best practices. Recommends priorities on implementation of best practices and coordinates these activities with the respective plant manager.
2. Leads material projects inside the plants. Supports and implements various tasks to improve magnet wire quality, production methods, and business processes in support of the Company’s Strategic Plan.
3. Develops training and trains plant personnel on Rea products and customer applications to enhance the support functions of the facilities to Rea’s customer base.
4. Trains Rea employees on customer contact etiquette, contact procedures and reporting processes (both internal and external) in coordination with the Plant Quality Managers in order to provide consistent, professional and efficient customer support.
5. Supports prioritization and validation of corrective actions (both internal and external) for the production facilities with a customer based focus.
6. Supports development of Rea plant managers’ relations with customer locations.
7. Designs, develops, and conducts Lean Manufacturing and Six Sigma training.
8. Completes problem solving projects for magnet wire processes using appropriate Six Sigma/ Lean Manufacturing methods and hands-on experimentation.
9. Leads, guides, and develops field compliance engineering team on performance assessments and problem solving with the customer’s manufacturing processes.
10. Evaluates, collects, and reports information on the capability and compliance of company products and competing products with customer requirements.
11. Performs such individual assignments as the Vice President may direct; establishes and maintains effective work relationships within the plants, the Company and the community; and maintains the professional competence, knowledge and skill necessary for the satisfactory performance of all assigned responsibilities.
Bachelor’s degree in Engineering or relevant field.
Ten (10) years of production or manufacturing experience; five (5) years of field experience with customer base.
In-depth knowledge of magnet wire products, equipment, manufacturing processes, business processes, and customer applications.
Six Sigma Green Belt and Lean Manufacturing practitioner preferred.
Microsoft Office (Word, Excel, Powerpoint, Access, Outlook); statistical software (Minitab).
People oriented and comfortable working the floor.
Excellent communication and analytical skills.
Ability to coach and mentor process and quality personnel.
Travel between 50-60% to plants and customer locations.
Metallurgical Engineer – Lafayette, IN (Posted 6/1/12)
Provides technical and engineering expertise for drawing, rolling, annealing, metal recovery, and liquid metal processes. Provides leadership in developing and maintaining copper and aluminum rod quality. Leads project teams and conducts tests on copper and aluminum rod and analyzes quality data. Leads project teams to evaluate, develop, implement, and oversee operations of new metal forming processes, including conform, continuous casting, and upcast. Leads teams to develop and validate cost saving opportunities on copper and aluminum rod. Works with suppliers to ensure the highest quality and most economical copper and aluminum rod for the magnet wire production process. Assists plants in solving quality and manufacturing problems associated with conductor metals.
Duties and Responsibilities
1. Develops, implements, and ensures utilization of metallurgical methods, procedures and specifications for raw materials, processing materials, finished products and equipment operation in manufacturing operations. Leads and participates in the development, design, and selection of process and control equipment.
2. Develops and executes metallurgical projects to control scrap, improve the manufacturing process, improve product quality, and reduce costs.
3. Provides technical and engineering leadership for copper and aluminum rod quality and vendor approval to North American magnet wire plants.
4. Provides process development and design leadership for new metal drawing/forming methods, including conform, continuous casting, and upcast along with metal recovery methods.
5. Works with suppliers on improving the quality of copper and aluminum bare rod in support of the magnet wire production process. Identifies and analyzes other potential sources of copper and aluminum bare rod.
6. Tests and evaluates core properties of copper and aluminum rod to ensure raw materials are suitable for the magnet wire production process.
7. Provides process engineering expertise for the improvement of drawing, rolling, conforming, continuous casting, and upcasting processes in an effort to attain highest quality conductor product for customers.
8. Provides leadership and expertise for product testing on metals to North American and International plant locations.
9. Supports and implements various tasks, projects, and actions in support of the Company Strategic Plan.
10. Leads and participates in Safety, Six Sigma and Lean team activities.
Master’s degree in Metallurgy or Material Sciences. PhD degree preferred.
Six Sigma Green Belt training. Lean Manufacturing training.
Fifteen (15) + years of metallurgy experience with an emphasis in copper and aluminum rod drawing, forming, rolling, continuous casting, etc and/or magnet wire experience.
Knowledge of core metal properties of copper/aluminum along with liquid metal chemistry/processing.
Ability to use statistical software (i.e. Minitab, etc.) and MicroSoft Office.
Domestic Travel (25%) and International Travel (10%)