Site STA Engineer at Ford Motor Company of Southern Africa

Job Description

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

Responsibilities
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
 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