Manufacturing Engineering Job Descriptions

Transcription

1 Manufacturing Engineering Job Descriptions

2 Manufacturing Engineer Title Body and Press Manufacturing Engineer Undergraduate Department Body and Press Units Location Vauxhall Luton Plant Brands Vauxhall, Opel, Renault, Nissan The Manufacturing Engineering group is responsible for the equipment, tooling and product changes within the Luton Plant, and is situated within either Body, Paint, General Assembly or Quality operations. Key Responsibilities: Involvement in Next Generation Vivaro studies. Involvement in Engineering Change implementation and management. Lead implementation of Predictive Maintenance technologies. Ensure that ME Process Standardisation is maintained. Support the Body unit in achieving World Class Spot-welding performance. Support the Plant Throughput Improvement Process (TIP). ME Process Standardisation to include QCOS (D11), PFMEA, Quality Standards (eg.d10), Lean Measurables. The successful candidate must demonstrate good communication, presentation and problem solving skills. They must demonstrate the ability to use their own initiative and show motivation to get the job done. They must also be comfortable with their presentation skills as they will be asked to present their project progress regularly to management. A good level of computer literacy, including Word and Excel, is also necessary. 2

3 Dimensional Engineer Title Dimensional Engineer Undergraduate Department Body Shop Location Vauxhall Luton Plant Brands Vauxhall The Manufacturing Quality Process department is responsible for technical problem solving on internal geometry and assembly tooling processes. As part of the department, the undergraduate will join the Body Quality Process Team and provide assistance or lead in a range of activities to support plant 6-sigma, ABC geometry quality metrics and Plant Global Customer Audit. The successful applicant will be involved in problem solving assignments and production line support. The Role: Translate 3D measuring results and drawings into actual assemblies and tooling processes. Use CMM data for problem solving Lead problem solving in Body Shop production Support 6-sigma & ABC geometry process to meet business targets Take responsibility for Quality processes within Body Shop Assist / lead development of Tomoana (nominal alignment panels) process Interpret and develop laser gauge measurement system Perceptron Robust documentation records of all problem solving During their placement the undergraduate will gain a good level of knowledge and understanding of the way in which the quality department works, and the tasks and interactions required to facilitate high quality production. There will be many opportunities to participate in training activities to develop skills that will be relevant for this role and in the future. Excellent communication and organisational skills, along with the ability to develop relationships with Managers and colleagues from different areas of the Plant. The individual should be highly motivated with good problemsolving skills and an analytical mind. A good level of computer literacy is required. 3

4 Production Support Engineer Title Production Support Engineer Undergraduate Department Body Shop Location Vauxhall Luton Plant Brands Vauxhall The Production Support group is responsible for the maintenance of equipment, tooling and plant within the Body unit. As part of this department the undergraduate will assume a full and active role in all aspects of the business. The Role: The successful applicant will be involved in many different roles with the following key responsibilities: a) The use of GM s Throughput Improvement Process (TIP) website to collate data and identify the top bottlenecks in the unit, which is then used by the maintenance teams to co-ordinate their activities. b) Development of maintenance function and help sheets to assist with day to day tasks and providing a structured approach to fault finding. c) Collating of minor fault data as a method for identifying potential major issues as well as current issues impacting on production volumes In fulfilling these key tasks the undergraduate will have the opportunity to experience several different areas and departments within the Body Shop giving them a broad and detailed understanding of the processes therein. The role this year will also involve the successful candidate integrating with the maintenance and engineering teams. The undergraduate will provide technical assistance in the implementation of the new production equipment for the next generation Vivaro. The role will be extremely varied and will suit a candidate interested in project management but who does not mind getting their hands dirty in a maintenance environment. Additionally, the undergraduate will get the opportunity to enrol on several courses, one of which is a statistical problem solving tool that requires a problem solving project to be completed to pass the course. The successful candidate must be able to demonstrate the ability to use their own initiative and show motivation to get the job done. They must be able to demonstrate good communication and problem solving skills. A good level of computer literacy, including Word, PowerPoint and Excel, is also necessary as it is used frequently. 4

5 Facilities and Central Maintenance Engineer Title Facilities and Central Maintenance Engineer Department World Facilities Group (WFG) Location Vauxhall Luton Plant Brands Vauxhall The World Facilities Group (WFG) encompasses the Luton Plant Facilities department, the Environmental department & the Central Maintenance department. WFG are responsible for the following: Maintenance and upkeep of all buildings and infrastructure (buildings, communication & security systems, emergency equipment, fire systems, lighting, pipes, pumps, tanks, lifting gear). Energy management & reduction of energy consumption across the Plant. All site mechanical & electrical utilities (water, compressed air, electricity, drainage, fuel farms, heating systems, metering, trade effluent). Maintenance of plant internal vehicle fleet & mobile equipment. Responsible for the admin of ISO14001 Environmental Management System and the site-wide waste management and housekeeping contracts. Central Maintenance group supporting the maintenance strategies of the maintenance teams across the whole of the manufacturing and facilities areas. Key Responsibilities Working within the Plant WFG Facility Engineering team as a Facilities & Central Maintenance Engineer, you will be responsible for daily liaison with our contract service providers, manufacturing teams & maintenance managers in Press shop, Body shop, Paint shop & General Assembly Units. Area of responsibility therefore covers the whole Luton site. Gain an in-depth understanding of the equipment and systems operating in the FM areas of responsibility and develop suggestions for efficiency and level of service improvements. Daily tasks will include playing a pivotal role controlling the plant Energy Management System. Plant currently spends around 8.5 million on its energy. Working closely with the Site Utilities Engineer, you will be responsible for understanding the plant energy infrastructure, monitoring energy consumption on a daily basis, identifying areas of waste & driving energy saving initiatives to reduce usage & cost. Includes generating & communicating regular energy reports to all manufacturing units & identifying top energy consumers across the Site. You will be required to Project Manage energy saving initiatives from cradle to grave, identifying areas of potential, carry out cost-justification of investment versus saving, produce specifications & implement engineering solutions to reduce energy usage throughout the Plant. You will provide technical support, engineering knowledge & problem solving skills to assist in resolving daily facility engineering issues within the Manufacturing units. Working closely with Maintenance Managers in the manufacturing units, becoming familiar with day to day maintenance issues, communicate lessons learned and best practices across maintenance teams, ensuring 5

6 teams are working as effectively as possible. Generate & communicate Plant Maintenance Newsletter throughout the Plant. Look for opportunity outside of the organisation for best practices that can be shared internally. You will be responsible for utilising the TIP Throughput Improvement Process, identifying plant bottlenecks, improving uptime & production throughput. Complete and record daily environmental monitoring. Conduct environmental inspections/audits/checks as required, e.g. above ground storage tanks (including ancillary equipment/infrastructure e.g. bund and alarm checks) and maintenance related environmental audits. Work with the units to improve environmental controls and infrastructure as part of the plants to ISO continuous improvement programmes. Become familiar with the Maximo maintenance IT scheduling system & utilise to document all of our environmental standardised task requirements. Complete Red-X technical problem solving apprentice class and a Red-X project in order to gain Red-X Apprentice level certification. Key Responsibilities You will have sound knowledge of mechanical or electrical engineering & be able to problem solve whilst working under pressure & to time constraints. You will have excellent communication skills, be able to work as part of a team & also to demonstrate the initiative to work independently when required. You must have the ability to be flexible in your working practices and have the motivation and tenacity required in order to get the job done. You must be able to evaluate problems and make sound judgements under pressure. A good level of computer literacy is required, with the ability to adapt to new programs where training is not available. 6

7 X82 Undergraduate Engineer Title X82 Undergraduate Engineer Department Plant Launch Team Location Vauxhall Luton Plant Brands Vauxhall Key Elements of the Role: Excellent Communication, problem solving and interpersonal skills Self-motivation and drive for results. An ability to work with minimal supervision Ability to make timely decisions Ability to work within the Cross Functional launch team on all aspects of the X82 Project A Strong learner who can quickly gain an understanding of the production processes within the manufacturing plant. Key Skills/Knowledge for the Role: Ability to communicate with all levels of the organisation from production, team member to senior management Strong organisation skills Knowledge and understanding of working with Auto CAD Strong planning skills and the ability to work under pressure and to urgent deadlines Excellent IT skills Ability to produce and present on key launch KPIs Key Qualifications for the Role: You should be working towards a relevant engineering degree. Be flexible to support shift work as required. Able to attend occasional business trips during project key phases. Ability to tailor communication styles to all levels of the business The ideal candidate will, during their 12 months placement, become an integral part of the X82 Launch Team. They will have their own roles and responsibilities within the group and will gain experience participating in a major real life product launch. Expected to generate a project relating to the business needs as well as complimenting their academic requirements. 7

8 Quality and Reliability Engineer Title Quality and Reliability Engineer Undergraduate Department Quality Operations Location Vauxhall Luton Plant Brands Vauxhall The Reliability group is responsible for the collection, investigation and reduction of the warranty created from the Vivaro and Movano commercial vehicles. It is situated within the Quality group and works closely with other areas of Quality and Manufacturing within the plant as well as the Aftersales group outside of plant. Key Responsibilities: Situated in the Quality Offices Reliability Team, you will be required to work on a number of key Quality objectives as seen in the responsibilities below. Collate, review and prioritise customer feedback comments to understand current level of real customer problems. Support and improve current standardised tracking system of customer defects Working alongside Quality and Manufacturing Engineers investigate, root cause and implement solutions for highest priority issues Take on specific long term quality issues as personal projects. Liaising with all areas of the business to communicate, measure and feedback results of quality improvements Working from standard warranty reports, communicate with and visit dealers to understand specific problems. During their placement the undergraduate will attend a training course on problem solving and will be expected to use this training to carry out a number of projects on specific problems and bring about timely solutions. As part of the problem solving activity, it will be necessary to devise a measurement technique to show the effect on improvements being implemented The successful candidate must be able to demonstrate excellent communication skills and develop relationships with colleagues from different areas of the plant. They must demonstrate the ability to use their own initiative and show motivation as the workload is determined by the candidates ability to find issues that need fixing. They must be able to demonstrate good problem solving and time management skills as large amounts of data is often required to be organised into logical groups and prioritise effectively. A good level of computer literacy, including Word, Excel and Access, is also necessary as these are used frequently. In an addition to the role, it will sometimes be necessary to contact Dealerships / Care Centres in different countries. In view of this, an ability to speak Spanish or Italian would be beneficial. 8

9 Quality Engineer Title Maintenance Co-Ordinator Undergraduate Department Quality Operations Location Vauxhall Luton Plant Brands Vauxhall The Quality Operations group is responsible for ensuring the build quality of the vans produced at set stages through the production process. They are also responsible for the recording and reporting out of defects. In addition to this the role is also responsible for all of the relevant GME procedures that relate to the departments. Key Responsibilities: Key member of the group with the expectation he will learn all of the inspection stations to obtain hands on experience of an assembly line. Report out to all levels of the organisation on a daily basis defects found Support production in hands on first level problem solving Led cross functional groups to solve complex problem solving Completion of a Red X training course, a problem solving tool which is then applied to a project. Implement and drive the use of proactive quality tools PFMEA Investigate and solve warranty issues. Investigate and solve production issues. Understand and audit Quality procedures both internal to Quality operations group and within other departments Identify cost reduction activities Identify and report out best practices to Europe Implement best practices recommended from Europe. The successful candidate must be able to demonstrate excellent communication skills and develop relationships with colleagues from different areas of the plant, as well as any necessary external customers. They must be able to demonstrate good problem solving and time management skills. A good level of computer literacy, including Word, PowerPoint and Excel, is also necessary as it is used frequently. However, this is a hands on job and the successful candidate should be willing to get fully involved in all aspects of day to day production. 9

10 Press Support Engineer Title Press Support Engineer Undergraduate Department Press Unit Location Vauxhall Luton Plant Brands Vauxhall, Opel, Renault, Nissan Press Operations are responsible for the production of key inner and outer sheet metal components for the current Vivaro van manufactured in Luton. The unit consists of 3 major press lines which manufactures around 1.24 million hits per annum. The Press organisation consists of 57 people with a mix of Managers, Engineers, Skilled Maintenance and Production personnel. Key Responsibilities Departmental control and planning for all Repair and Overhaul \ Capital request projects, short, medium and long term X82 Management of departmental Planned Maintenance System using Maximo 7 which include both preventative and Predictive Inspections Responsibility for departmental Plant Floor IT Systems including patch and software updates Shop Energy usage Current Model TIP Data Tracking Improvements Continual improvements of the automated downtime data logging for Press Planned and Predictive Maintenance - Maximo 7 Rollout to Shop Floor including training of unit Maintenance personnel Press Shop Plant Floor 'Cimplicity' system - Improvements and further implementation Introduce Maintenance Shadow boards into MARS for Press. Maintenance Breakdown Response \ Support Tools - Tools \ Tackle centrally stored and tracked (MARS) ILM Continual development of the drawing \ documentation index in archive room. Ensure shop floor has sufficient documentation and place all master documentation from floor to ILM archive. Plant Floor Systems - UD&C continued rollout to other PC's in Press ensuring auto save of data to servers Lifting Tackle - Improve efficiency and reduce quantities in use to still meet requirements of Maintenance teams. Centrally locate unused equipment for possible plant usage. Unit energy consumption investigation and improvements for energy efficiency Continual updates to A5 Maintenance Handbooks and functional documentation Next Generation Vivaro Project Support Involvement in Press Line project activities 10

11 Integration of new equipment \ tooling changes into current maintenance processes Shop layout changes - Die Shop move, maintenance stores relocation etc. Energy usage mapping and improvements for cost savings. An ability to communicate effectively with all functional groups within GMML, GME, and operate appropriately at all levels. An ability to communicate effectively within the team environment A high level of computer literacy Excellent communication skills Exceptional planner Will be able to work alone An ability to self-motivate Ability to have strong capabilities of problem solving 11

12 Paint Process/Quality Engineer Title Paint Process/Quality Engineer Undergraduate Department Paint Shop Location Vauxhall Luton Plant Brands Vauxhall The Process, Applications and Quality group in the Paint Unit are responsible for the Control and monitoring of all Sealer, Pre-coat and Paint applications, including material control, anti-corrosion and repair facilities. They are also involved with GCA and Warranty monitoring and Quality of output of Paint Shop product. The Role: You will be working on different Unit based projects and initiatives. In each of these projects you will be responsible for the Development, Planning, Coordination, &, trial / introduction phases for the X82 model, under the guidance of an experienced Paint Process Manager. Creating solutions and applying lateral thinking will be a major part of your role along with dealing directly with production, maintenance depts. and production support groups. Proven Leadership and vision Good communication and interpersonal skills Ability to communicate at all levels. Proven record of data driven problem solving (eg; Red X) Strong planning skills and the ability to work under pressure and to urgent deadlines. Good project management skills. The ability to identify concerns and areas for improvement, solve problems and lead a problem solving team with detailed follow up. Confidence in dealing with multi-functional groups and suppliers / contractors. An understanding of validation and monitoring of Paint Shop facilities and Paint Shop processes. Managing the introduction of any changes in process and process related materials. Ensure products meet marketing and quality requirements. Be fully conversant and understand control and monitoring of COSHH within the Paint Shop. An understanding of D11 QCOS and PFMEA, BIQ and Lean Measurables. 12

13 Maintenance Co-Ordinator Title Maintenance Co-Ordinator Undergraduate Department Paint Shop Location Vauxhall Luton Plant Brands Vauxhall The Manufacturing Engineering group is responsible for the equipment, tooling and product changes within the Luton Plant, and is situated within either Body, Paint, General Assembly or, Quality operations. Key Responsibilities: You will be working on different plant based projects and initiatives as well as having individual daily tasks to complete. In each of these projects you will be responsible for the Development, Planning, Coordination, &, Implementation phases, under the guidance of an experienced Engineer. Creating solutions and applying lateral thinking will be a major part of your role. You will provide technical support and manufacturing knowledge to assist in resolving capacity, design, manufacturing and quality issues. Key roles include the following: Taking on the through put improvement process (TIP) data collection and presentation for the top bottlenecks within the shop Predictive maintenance including vibration and thermal analysis Use minor faults tracking to monitor problem areas Improve facilities, coordination and efficiency within maintenance processes Validation and testing of facilities and manufacturing process. Condition monitoring of equipment such as conveyors Being part of a planned maintenance system and learning maintenance processes Learn to use Maximo Improve knowledge sharing between the manufacturing engineers in the department. The successful candidate must be able to demonstrate the ability to work as part of a team and to show flexibility in their working practices. They must be able to plan, analyse and make sound judgements under pressure. Practical knowledge of manufacturing and/or electrical engineering and good communications skills are essential. A good level of computer literacy, including Word and Excel is also necessary. Working knowledge and an understanding of technical drawings would be useful. 13

14 Manufacturing Engineer Title Manufacturing Engineer Undergraduate Department General Assembly Location Vauxhall Luton Plant Brands Vauxhall, Opel The Role: The Manufacturing Engineering group is responsible for the equipment, tooling and product changes within the Luton Plant, and is situated within either Body, Paint, General Assembly or Quality operations. Key Responsibilities: Tracking defects and reporting them to production supervisors as well as conducting independent investigations on these defects. Finding timely solutions to problems on the production line by liaising with other manufacturing engineers, maintenance or production personnel. Providing manufacturing knowledge to assist in resolving these problems. You will also assist in the maintenance and updating of Process Failure Mode Effect Analysis (PFMEA) within General Assembly. This is a measure of the failure analysis of processes and the prevention of failures. Furthermore, the candidate will be involved with Process Capability studies ensuring a target level of quality for manufacturing tooling and equipment. Lean Measurables and Change Management are two further key areas, supporting engineering change and working towards continual improvement of the manufacturing processes and equipment. The successful candidate must demonstrate good communication, presentation and problem solving skills. They must demonstrate the ability to use their own initiative and show motivation to get the job done. They must also be comfortable in with their presentation skills as they will be asked to present their project progress regularly to management. A good level of computer literacy, including Word and Excel, is also necessary. Preferred Area of Study: Engineering Mechanical, Electrical, Manufacturing, Automotive 14

15 General Assembly Project Engineer Title Project Engineer Undergraduate Department General Assembly Location Vauxhall Luton Plant Brands Vauxhall, Opel, Renault, Nissan The Role: This role is based within the General Assembly area of Vauxhall Luton Plant. There are two main projects that will be assigned. You will be given training in how to apply the company s problem solving process and the procedures relating to standardised working practices. In support of the manufacturing shift managers you will highlight areas where standardised work needs improving and assist in the implementation of changes. Key Responsibilities: Daily Tasks Undertake standardised work audits comparing what is required to what is occurring. Compare shift to shift and operator to operator. Recording issues for resolution. Develop a process to gauge the compliance of each station to standardised work that can be used to confirm a station is certified as complying with all processes and procedures after changes to standardised work occur. TIP process, update and analysis daily data and use this to highlight bottlenecks and help solve the issues. CIP, work as part of the CIP team, identify waste within the current process and help eliminate. Assist GA Business Manager in Green zone / SPS data collection and analysis. Main Project You will be assigned the responsibility for resolving one of the top 5 Quality issues. This will include: o Understanding the defect o Determining the physics of failure o Design and testing of containments o Develop action plans to investigate how to prevent it o Develop and implement countermeasures o Tracking and monitoring of results Skills Developed: Red-X Training, a set of skills developed to analyse and take action on a project Professional Learning, Networking and Presentation Skills Knowledge of TIP and Bottlenecks Engineering Solutions Life Skills; i.e. Time Management and Organisation 15

16 General Assembly Project Engineer Title General Assembly Project Engineer Department General Assembly Location Ellesmere Port Plant General Assembly is the largest unit on the plant and fits over 2000 components into each car. At present it produces one vehicle every 71 seconds, therefore the equipment requires extremely high uptime and reliability, Key responsibilities: Engineering activities in General Assembly Maintenance to include Maintenance Engineering to improve equipment reliability. Maintenance PFMEA studies Problem solving and countermeasure implementation Project planning for equipment improvement. Energy Saving studies attendance and feedback from Weekly Energy meetings Key Job functions - TIP Process Throughput analysis Implementation of Predictive technologies Red X problem solving Undergrad project Engineering issue problem solving The trainee will be primarily involved in the continuous improvement of maintenance systems in terms of quality and throughput, using a range of equipment and the activities listed above. The trainee should hope to gain experience in maintenance and planning techniques within the unit. The trainee will gain experience of working with many different levels of personnel from process engineers and supervisors to maintenance technicians and vendors. There is also the opportunity to attend training courses alongside work colleagues. A background in electrical/mechanical engineering is essential, Should also be computer literate Good communication skills Ability to work in a small highly motivated team as part of a larger team environment. Preferred area of study: Mechanical/Electrical engineering 16

17 General Assembly Planning Engineer Title General Assembly Planning Engineer Department Manufacturing Engineering - General Assembly Planning Location Ellesmere Port Plant The Manufacturing Engineering Department at the Ellesmere Port Plant is responsible for the provision of production facilities and processes into plant. This department carries out the plant co-ordination of new model introduction, and ongoing day to day changes. They also lead investigation into new tooling and quality problems, as well as implementing quality and efficiency improvements. Key responsibilities: Initial line sequencing and material layouts New equipment Project Management, Specification, procurement, installation, and commissioning Project cost estimating for new models, model facelifts, and new engineering changes Lead role in tryout and pilot build activities at Russelsheim plant, Germany Liaise with design team (ITDC) and home plant team Implement quality and efficiency improvements Implementation of day to day running changes The trainee should hope to gain an understanding of the planning engineering processes used within the plant. They will develop many skills and gain experience in a realistic engineering environment. They will be given an opportunity to use their initiative and put forward new ideas. Over the year various projects will be required to be carried out (both group and individual) involving the installation of new equipment or processes around the plant, with appropriate levels of support given to ensure the undergraduate gains maximum development. Ability to communicate effectively with a wide range of people Planning and Organising Ability to use own initiative Computer Literate. Preferred area of study: Engineering based degree. 17

18 General Assembly Process Engineer Title General Assembly Process Engineer Department General Assembly Location Ellesmere Port Plant General Assembly is the largest unit on the plant and fits over 2000 components into each car. At present the Unit has responsibility for the Astra 5 door hatchback, Astra Sports Tourer launched in September Key responsibilities: Engineering activities in General Assembly include Quality Engineering ensuring efficiency and throughput. Data Analysis of Trends leading towards solutions for specific technical issues Statistical Engineering problem solving and countermeasure implementation Project planning for efficiency and throughput. Support and planning in preparation for the launch of D2XXX (next generation Astra) The trainee will be primarily involved in the continuous improvement of systems in terms of quality and throughput, using a range of equipment and the activities listed above. The trainee should hope to gain experience in manufacturing and planning techniques within the unit. The trainee will gain experience of working with many different levels of personnel from process engineers and supervisors to maintenance technicians and vendors. There is also the opportunity to attend training courses alongside work colleagues. A background in manufacturing/electrical/mechanical engineering is essential, Should also be computer literate Good communication skills Ability to work in a small highly motivated team as part of a larger team environment. Preferred area of study: Manufacturing/Mechanical/Electrical engineering 18

19 Health and Safety/Environment Engineer Title Health and Safety/Environment Engineer Department Health and Safety Location Ellesmere Port Plant Job Description Health and Safety/Environment Engineer Key Responsibilities: Internal & External audits: Temporary Paint Shop Rep & ISO Audits Preparation for the GMAS audits Managing, training and supporting all environmental representatives on site Safety training coordinator and environmental training improvement coordinator Increase the amount of positive media for environmental team by writing articles for the local newspaper on the success of the environment team at Ellesmere Port. Support waste management Assist with collecting data and writing annual environmental reports to the council COSHH ( Control of Substances Hazardous to Health co coordinator and assistant auditor) Accident Investigation Contractor Health and Safety Induction Training Health and Safety Statistics Reporting Data Collection As Hoc Projects The trainee should hope to gain an understanding of the environmental and general safety processes used within the plant. They will develop many skills and gain experience in a manufacturing environment. They will be given an opportunity to use their initiative and put forward new ideas. Over the year various projects will be required to be carried out (both group and individual) with appropriate levels of support given to ensure the undergraduate gains maximum development. Ability to communicate effectively with a wide range of people Planning and Organising Ability to use own initiative Computer Literate. Preferred area of study: Business/ Environmental Studies/Engineering based degree. 19

20 Material Planning Engineer Title Material Planning Engineer Department Supply Chain Location Ellesmere Port Plant The Supply Chain Division is responsible for making sure that all the production process to build our cars is not constrained for any material, and holds inventories based on lean principles and Just in Time philosophies. This means that within Supply Chain in a Fast Paced manufacturing operation is a pressurized role. Each day is different but as part of a team working with thousands of part numbers, that handles 700+ trucks of material arriving from all over the world per week, the only thing you can be certain of is that there will be daily challenges. Responsibilities: Analyse the current store material location sizes & optimise Focus the layout of store to maximise efficiency Work with the Material Handling department to create Task Information Sheets to help move towards standardised lean processes within the unit. Analyse Off Load Checking and Dispersal to reach efficiency targets Create TPM for mobile equipment programme working as the driving force. The trainee should hope to gain an understanding of the overall Lean Supply Chain used within the plant. They will develop many skills and gain experience in a challenging logistics environment. They will be given an opportunity to use their initiative and put forward new ideas but, with appropriate levels of support given to ensure the undergraduate gains maximum development. Ability to communicate effectively with a wide range of people Planning and Organising Ability to use own initiative Strong Interest In Lean Manufacturing & Supply Chain Ability to work to deadlines Desire to work on shopfloor Computer Literate. Preferred area of study: Engineering based degree. 20

21 Paint Unit Sealer Engineer Title Paint Unit Sealer Engineer Department Paint Unit Location Ellesmere Port Plant The Paint Unit at the Vauxhall Ellesmere Port Plant is a Key production unit for the Astra Hatch & Astra Sports Tourer. The unit receives the car body shell, which is then cleaned, electrocoated, sealed, primed and painted, utilizing the latest robotic and computer controlled processes. Key Responsibilities: Day to day responsibility for vehicle preparation under body corrosion, sealer and wax functions including the monitoring and control of process boards Usage Monitoring- emphasis on cost saving measures Sealer Quality response- Dealing with quality issues as they arise either internally (directly on the sealer desk or within Paint unit) or from external customers (General Assembly Global Customer Audit, water test and warranty) New model launch the requirement to be part of an interactive team responsible for installation and commissioning of new robotic cells for the launch of the Next-Generation Astra Design Development and management of sealer based tooling and production aids. This will include nozzles, stands, prototypes tools, jigs and fixtures to maintain or improve current operations. Unit responsibility for Warranty responding to customer concerns and implementing pro-active measures to prevent recurrence Presentation of practical problem solving measures in Audit. Daily Paint unit reports Assisting with trials and quality checks as required. Administration of the unit suggestion scheme Administration of the unit scrap process The trainee should hope to gain an understanding of the processes used within the paint unit. They will develop skills and gain experience in a realistic engineering environment. They will be required to use their initiative and put forward new ideas. Over the year, additional projects will be required to be carried out (both group and individual), with appropriate levels of support given to ensure the undergraduate gains maximum development. Ability to communicate effectively with a wide range of people Planning and Organising Ability to use own initiative Computer Literate. Preferred area of study: Engineering based degree. 21

22 Press Shop Undergraduate Title Press Shop Undergraduate Department Press Shop Location Ellesmere Port Plant The press unit is responsible for pressing body panels for each Astra variant. They supply panels for production of the 5 door Astra at Ellesmere Port and also other Astra variants produced globally. Key Responsibilities: Engineering activities in the press unit include; Line Automation technical support Electrical, PLC, Robot technical support Safety Standards, legislation and procedures Basement conveyor systems Crane issues COSHH Co-ordinator Die Movement Equipment Support problem solving efforts for quality and productivity issues Link to customers for quality complaints Link to ITDC and local ME and new model dies Co-ordinates unit for ISO 9002 and ISO compliance Planning of shutdown activities Tryout press support Die wash issues Bailer machinery A background in Mechanical/Manufacturing engineering is preferred Ability to communicate effectively with a wide range of people Planning and organising Ability to use initiative Computer literacy Preferred area of study: Engineering based degree. 22

23 Quality Engineer Title Quality Engineer Department General Assembly Location Ellesmere Port Plant The Quality Engineering group is responsible for the quality of incoming supplier parts and the introduction of product engineering changes within the Ellesmere Port plant. Key Responsibilities: Key member in high profile projects working to investigate and resolve real problems. Work closely with the Global Customer Audit department to improve and resolve quality issues. Working with external suppliers. Completion of a Red X training course, a problem solving tool which is then applied to a project. Support meetings with staff and suppliers. Oversee approval of new parts and part changes. Assist suppliers in maintaining quality of supplied parts. The successful candidate must be able to demonstrate excellent communication skills and develop relationships with colleagues from different areas of the plant, as well as any necessary external customers. They must be able to demonstrate good problem solving and time management skills. A good level of computer literacy, including Word, PowerPoint and Excel, is also necessary as it is used frequently. Working knowledge and an understanding of technical drawings would be useful, German speaking is not essential but preferred. Current Undergraduate Stephen Andrews What have I gained from the placement? Valuable work experience with an automotive manufacturing company. Experience working in a highly motivated team and individually to solve problems. Professional presentation skills. Highlight of my placement year! Participation in the undergraduate community project. Working in the QA department across the plant. Practical courses offered to develop understanding of and appreciation for manufacturing procedures and principles. A great undergraduate group, small enough to get to know everyone. Real responsibility with involvement in high priority projects. 23

24 Central Maintenance and Body Shop Engineer Title Central Maintenance and Body Shop Engineer Department Manufacturing Plant wide Location Ellesmere Port Plant The Central Maintenance team at the Ellesmere Port plant is responsible for the maintenance of machinery in all of the production units. Key responsibilities: Implementation of Predictive Maintenance (Thermography) This will include: Research Thermographics. Develop, Plan, Process, Document and Test the implementation of Thermography in one control area. Implement the scheduling into Maximo (preventive maintenance Scheduler).. Final Process to be documented in a comprehensive training package. Train future users. Engineering activities in the BodyShop include: Robotic equipment CO2 and spot welding equipment Pneumatic systems Cycle time improvements Uptime improvements - condition monitoring Constraints / Bottleneck analysis System Error proofing Equipment evaluation Spare equipment purchase The trainee should hope to gain an understanding of the maintenance processes used within the plant and primarily involved in the continuous improvement of systems in terms of quality and throughput. They will develop skills and gain experience in a realistic engineering environment. They will be required to use their initiative and put forward new ideas. Over the year additional projects will be required to be carried out (both group and individual) involving maintenance around the plant, with appropriate levels of support given to ensure the undergraduate gains maximum development. Ability to communicate effectively with a wide range of people Planning and Organising Ability to use own initiative 24

25 Computer Literate. Preferred area of study: Manufacturing/Mechanical/Electrical engineering 25

26 Strategy & Planning Layout Engineer Title Strategy & Planning Layout Engineer Department Manufacturing Engineering Location Ellesmere Port Plant The Manufacturing Engineering Department at the Ellesmere Port Plant is responsible for the provision of production facilities and processes into plant. This department carries out the plant co-ordination of new model introduction, and ongoing day to day changes. They also lead investigation into new tooling and quality problems, as well as implementing quality and efficiency improvements. Key responsibilities: Preparation of concepts, Site drawings and Shop Floor layouts to maximise efficient use of all areas. Preparation of cost estimates for major projects Project management including allocation of tasks & follow Liaison with other Planning Departments, Production, Safety, Supply Chain, Quality, Outside Suppliers, Trade Unions etc. to achieve successful agreement & implementation of all layout requirements Site supervision of shop floor installations Presentation of layouts, reports, timing schedules etc. to Senior Management The trainee should hope to gain an understanding of the planning engineering processes used within the plant. They will develop many skills and gain experience in a realistic engineering environment. They will be given an opportunity to use their initiative and put forward new ideas. Over the year various projects will be required to be carried out (both group and individual) involving the installation of new equipment or processes around the plant, with appropriate levels of support given to ensure the undergraduate gains maximum development. A flexible approach in dealing effectively with a wide variety of problems Good planning and problem solving skills Effectively prioritise workload Be capable of working on their own initiative with minimum supervision Sound interpersonal skills and ability to work as part of a team Excellent verbal and written communication skills Strong Computer skills A working knowledge of AutoCAD would be an advantage. Preferred area of study: Manufacturing or Mechanical Engineering based degree 26

27 Paint Unit Operational Support Engineer Title Operational Support Engineer Department Manufacturing Paint Unit Location Ellesmere Port Plant The Paint Unit at the Vauxhall Ellesmere Port Plant is a Key production unit for the Astra. Astra Sports Tourer and Van. The unit receives the car body shell, which is then cleaned electrocuted, sealed, primed and painted, utilizing the latest robotic and computer controlled processes. Key responsibilities: Working to review critical spares and ensure identification of critical spares to suppliers Review usage of spares working to reduce the inventory where possible. Manage the Maintenance technical safety and process training plans, Organise continuous improvements plans through the use of Go-fast meetings. Co-ordinate Energy Reduction Meetings, implement plant and local initiatives with support from Maintenance, Process and Production Supervision and Teams. Development of Preventative Maintenance Procedures and Schedules for new and existing Equipment and machinery inc Robotic Sealer and Paint Application Robots, conveyor systems and body treatment process s. Involvement in development and introduction of Predictive maintenance programmes such as vibration analysis, thermal imaging and trend recording. Assist with Development of Maintenance Risk Assessments and improve Safe Working Practices. Development and Implementation of Action Plans using Throughput Improvement Process to improve Unit efficiency and reduce process downtime. ( TIP ) The trainee should hope to gain an understanding of the Paint processes used within the plant. They will develop many skills and gain experience in a realistic engineering environment. They will be given an opportunity to use their initiative and put forward new ideas. Over the year various projects will be required to be carried out (both group and individual) involving the installation of new equipment around the plant, with appropriate levels of support given to ensure the undergraduate gains maximum development. Ability to communicate effectively with a wide range of people Planning and Organising Ability to use own initiative Computer literate Preferred area of study: Engineering based degree 27