Engineer - Process (Battery Pack Value Stream)

Bosch has been present in Malaysia since 1923, represented by Robert Bosch Sdn Bhd, with offices located in Selangor and Penang. In Malaysia, Bosch has diversified businesses in Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The company has three manufacturing plants in Penang providing Car Multimedia, Power Tools and Automotive Steering systems. In 2017, Malaysia contributed sales of RM 615 million (127 million euro) and employed more than 2,800 associates. Job Summary • Responsible for new product line setup and release. • Plan for MAE and EWAK investments related to workstation and accessories for new and existing lines. • Define, purchase, set up, perform trial run and buy off for all workstations and accessories of new products. • Prepare workstations layout, set up workstation, prepare line release documents and perform manufacturing line buy off before Pilot Run or mass production. • Perform Machine and Process Capability Study to ensure machines and processes meet the capability requirement during mass production. Identify and introduce SPC on certain processes whenever applicable. • Train and guide trainers, supervisors and maintenance personnel by transferring technical and process know-how. • Monitor and supervise VSE technician performance to ensure efficiency in value stream improvement activities and processes. • Responsible for process improvement project in production through time study - VT improvement, direct productivity improvement, ergonomic, workstation, machine and technology improvement and update management on the improvement result. • Support production in achieving the effectiveness, output, IDC and quality target through continuous improvement activity. • Liaise with maintenance personnel for maintenance plan set up and spare parts replacement for existing machine used in production. • Involve in failure analysis of production FOR and advise failure analyser on the disposition of the rejected parts. • Involve in Sales Driven Activity (SDA) projects and prepare supplement line release documents for mass production. • Provide support for quality problem resolution through problem solving skills PSS or 8D. • Monitor, report of KPI’s in timely manner and establish action plan. • Optimizing equipment and processes to maximize output & quality and minimize cost. • Mentoring junior Value Stream Engineer (VSE) in new product development processes, improvement activities and system application (eg: SAP, MES system, etc). • Actively participate in internal and external audits by ensuring up-to-date documentation, production system compliance and line readiness to support successful audit execution. • Prepare and deliver improvement project presentations to internal and external stakeholders during reviews, management meetings, and stakeholder visits to ensure alignment and effective communication of project progress and outcomes. • Act as the proxy for the VSE Section Head during periods of absence, ensuring continuity of operations, decision-making and stakeholder communication. Job Scope 1. New Product Introduction • Responsible to ensure successful transition of new product development from Front End Process (FEP) to manufacturing from C sample build, D sample build to Start of Production (SOP) until product end of life (EOL). • Responsible to ensure product is manufacturing ready from the aspect of manufacturing budgeting, hardware (workstations, line setup, MAE & EWAK), software (machine automation) and people (operator training, technical support competency). • Responsible to ensure the new product transition to manufacturing from SOP able to meet the safety, quality (4Q), cost (Internal Defect Cost, First Pass Yield) and delivery (meeting shipment and delivery target). • Represent manufacturing and contribute in all New Product Startup meeting all critical milestone process in the Project Management Plan e.g. Quality Gates (QG), Product FMEA/DFM and DFMA. • Lead in Process FMEA (from Project Release to Launch Release to Delivery Release), Value Stream Design (VSD), Scaling (SCAL), Lean Line Design (LLD) and Flow-orientated Layout (FOL), working closely with PGL coordinator during the Project Conception phase. (Kickoff to Project Release). • Plan production layout according to BPS principles meeting the cost, quality, time, capacity and logistic requirements (component packing e.g. PFEP info) of the project. • Design manufacturing plan including the budget/cost (as input to project calculation) and design, spec, ordering, setup and qualify for production release of MAE, EWAK, tools, software automation for the new product to meet the safety, ergonomics, ESD protection and process capabilities (Cmk,Cpk & GR&R), which include resistance welding pull off force, technical documentation (PQI, Control Plan, Setup document, In process checklist). • Establish, or optimized if already exists, resistance welding parameter, Line balancing, prepare VT Summary, Operator Balance Chart, Standardize Work with evaluated time studies for new products. • Manage the Engineering build and lead the pre-pilot (C ample), pilot build (D sample) and SOP by schedule, organize, build and analyze according to Project Management Plan and prepare report. • Prepare, update, and issue all Manufacturing Engineering documents: PQI, Visual Aids, In Process Checklist Set Up Plan, Line Balancing, Process FMEA, PQP, PWI, HIRADC and Line Release Documents. • Prepare training module and test paper for new products, train and certify the trainers base on the module. • Train and guide the Production/Process engineer/Supervisor and Maintenance on processes, equipment and machine know how during Pre-Pilot, Pilot build. • Liaise with maintenance section for maintenance plan and spare parts replacements during Line Release process. 2. Operation Support • Responsible for overall manufacturing process compliance from the safety,…