The Staff Project Engineer - casting & forging (hereafter, this position) is responsible for providing direct technical and engineering support for casting & forging process development / validation and associated Supplier support. This position must develop a strong working knowledge of materials policies and procedures established by Smith & Nephew and work with global project teams to maintain compliance and alignment with project related material specifications.This position will interact, on a daily basis, with Project Manager's, QE's, ME's and PDE's to support casting & forging materials project related issues, while supporting the development of associated casting and forging processes to support the global business needs. This position will support on-going casting & forging (hipping) process improvements, as appropriate and in a timeline manner.This position should check and review capability assessments related to casting and forging projects, meanwhile managing the microstructure, chemical, mechanical testing, to include measurement system and process capability analysis. This position will help to trouble-shoot or run Design of Experiments on any special processes and equipment to improve/correct capability.This position should audit and oversee internal and third party materials lab for X-Ray inspection, testing correlation, and casting/forging material inspection management etc. This position will work alongside or with the material suppliers and Smith & Nephew factories to develop casting/forging inspection.This position will work within the Materials Policies and Procedures established by Smith & Nephew with the good understanding of the national and international organization standards that define the Casting & Forging materials requirements and testing.This position will communicate any revisions to associated materials standards to Management, while assisting in developing and implementing appropriate action plans to align with the latest revisions to materials standards.The position shall work with casting & forging global suppliers & internal teams to support; - Casting and Forging product qualifications, action plans, process development, validations and on-site audits focusing on technical processes. - Conduct thorough technical reviews, at part level, to assess if casting & forging supplier’s processes are capable and in-control. - Lead and conduct defining validation and verification requirements for established, new, and revised casting & forging(hipping) processes.- Participate in post audit actions to support casting & forging Supplier Corrective Action Request (SCAR).- Develop casting and forging suppliers to meet SN standards and reliability requirements whilst working with SN purchasing, manufacturing, materials, and engineering teams.- Work with assigned casting & forging suppliers to improve On Time Delivery and Quality Performance to target levels. - Understand and communicate DoE, PFMEA, Root Cause Analysis, Process Capable, and In Control principles conducive to efficiencies and continuous improvement with casting & forging supplier deliverables. - Champion problem solving and root cause analysis activities with casting & forging suppliers to avoid repeat failures - Resolve day-to-day issues associated with casting & forging supplier problems, including but not limited to quality of product, delivery schedules, and cost improvement, etc. - Work with QA team and supplier recovery team to gather, analyze, and support actions for any related field issues for assigned materials suppliers - Lead required problem-solving efforts to eliminate casting & forging process related complaint issues.These are non-essential job duties and responsibilities as assigned by the Manager:This position may have to support training and share the necessary knowledge to perform the materials laboratory functions, administrative functions, and report writing.This position will be assigned to special projects and/or production by the Department Management that is commensurate with an intermediate level of difficulty.
sWorks on Projects and determines process evaluation, executes audits, analyzes data, confirms the improvement plan, and writes technical reports on findings.Provides technical and engineering support for Casting & Forging Development, Manufacturing, Quality, and Suppliers as directed.Initiates, performs as needed, and reviews Smith & Nephew and Supplier certifications or other technical documentation for laboratory testing in support of casting and forging materials or processes.Coordinate with internal and external stakeholders to determine casting & forging validation requirements, review validation protocol, manage the validation process, approves validation reports, as requiredDevelops process validation plans and oversees the implementation (URS, FDS, IQ, OQ, PQ) related to casting & forging suppliers & any associated internal processesPerforms internal and external audits associated with validation activities for casting and forging projects, and manage supporting improvement plansAssists with casting & forging quality inspection/control, process dimension and material inspections, insures that suppliers are in compliance with corporate, QSR, ISO, ASTM, and other regulatory compliance requirementsSupport and perform metallography that involves cutting, grinding, polishing, etching, and evaluating microstructures for the related materialsInterfaces with Outside Laboratory Contractors, Supplier Quality material Engineers, Manufacturing Engineers, Quality Engineers, and Management to review processes, determine material testing requirements, and confirm testing results.Performs other duties as assigned.
Travel50%-75%EducationBS (MS preferred) in Engineering, Science, or related field plus 6+ relevant yearsLicenses/CertificationsASQ certified Quality Engineer, AMS Metallurgy Certification or Greenbelt/Blackbelt Six Sigma Certification a plusExperienceTo perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required.Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.Medium or high level of expertise in Casting and Forging processes and equipment such as: Vacuum and Atmospheric Casting and Drop Forging Processes, Maintenance, Melting and Pouring Practices, post-forging Hipping process, Time and Temperature controls and Chemical/Mechanical/Metallography testing/validation.Five (5) years’ experience in materials management in a foundry manufacturing environment preferredThorough understanding of the QSR and ISO regulatory environmentThorough understanding of ASTM (American Society for Testing and Materials)Demonstrated knowledge and understanding of complex GD&T, measurement system analysis and tolerance stack analysisStrong and in-depth knowledge of problem-solving techniques for casting and forging (hipping) components preferred, have knowledge of key failure modes for casting and forgings (hipping) processes, problem diagnosis and resolution, associated standards and tolerances for each process.Familiar with casting and forging tooling to know its possible impact to failure/NC conditions, but not required to directly design/modification of tooling.Requires organizational and time management skills.Ability to understand advanced mathematical concepts, e.g. probability, statistical inference, calculus, and algebra.Data Analysis and Critical ThinkingAn ability to work independently.Excellent verbal and written communication skills.Knowledge of manufacturing processes and/or experience with laboratory equipment in medical device operations.CompetenciesProficiency in Windows and Microsoft Office applications (Word, Excel, PowerPoint, Outlook) SAP is a plus.OtherPHYSICAL DEMANDS:The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.This position may spend approximately forty percent (40%) percent of the time walking or standing. Twenty-five percent (25%) of the time may be spent at a computer keyboard. This position must be able to speak and hear well enough to communicate effectively.Since the position involves laboratory testing and manufacturing equipment and processes, this position must be able to perform and have the ability to perform basic laboratory functions and testing, and be able to operate manufacturing equipment as needed. This position must be able to perform testing utilizing chemicals that are needed for the required tests. In performing the duties in the laboratory, it may be necessary to lift up to 25 pounds.Requires use of hands and arms to operate lab equipment, manufacturing equipment, computers, copy machines, and telephone.Observation and evaluation of materials and testing requires that this position has excellent or corrected vision.LANGUAGE:This position must be able to speak and write effectively in English to support global communications, ability to speak and write in Mandarin is a plus