Job Description

Job Description: EnerSys is the global leader in stored energy solutions for industrial applications. We have over thirty manufacturing and assembly plants worldwide servicing over 10,000 customers in more than 100 countries. Worldwide headquarters are located in Reading, PA, USA with regional headquarters in Europe and Asia. We complement our extensive line of Motive Power and Energy Systems with a full range of integrated services and systems. With sales and service locations throughout the world, and over 100 years of battery experience, EnerSys is the power/full solution for stored DC power products.

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Job Purpose

Reporting directly to the Site Engineering Manager, the Senior Project and Design Engineer will work in closely with Process Engineering, Technical, Production, Product Design and Quality team to ensure all CapEx projects and new products or existing products transition from Design or other sister plants to Production seamlessly by executing projects in new tooling, and assembly process design and commissioning in readiness for SOP.

Essential Duties and Responsibilities

Lead the development of new processes, from early-stage product concepts to building product samples in line with New Product Introduction (NPI) procedure, Quality system and Development Process.
Works with Engineering Design and Senior Manufacturing Engineering teams to ensure optimum product and process design for manufacturability for New Product Introduction.
Responsible for tooling design and maintenance of tooling drawings database.
Help with Design of small assemblies or subassemblies for existing machines
Carry out engineering and design analysis using ANSYS and other FEA tools.
Lead the development and design of manufacturing systems and validate design
Supports development of associated documentation and estimates of manufacturing cost
Contribute as a key member of strategic to allocated work-streams within technical projects to meet project targets and ensure product exceeds customer expectations and operational needs.
As a key member of the engineering team, investigate all manufacturing solutions and liaise with Process Engineering Technical, Production and Quality to ensure agreed production systems are in place.

Key Responsibilities

Develop technical specifications for new manufacturing systems and machinery and write invitation to tender documents.
Compile detailed cost estimates and agree budgets with engineering manager for capital request.
Advise and coordinate with the technical and process engineering team on any new equipment, tooling, process design, process changes/modifications etc required for new products or process improvements ensuring the lead times are considered against project plans for product launches
Review existing manufacturing systems and select appropriate modern manufacturing techniques and implement to drive efficiency, cost and quality improvement
Required to make decisions within remit above and to escalate issues with significant risk/implication to the Engineering Manager.
Lead and take ownership of all site projects from specification development, concept design, detailed design, cost estimates, tender, sign off drawings, FAT, SAT, commissioning, validation, training, SOPs and beneficial operation handover.
Train and mentor junior engineers and apprentices.
Task managing other engineers and technicians and reviewing the technical aspect of assigned projects task to ensure project objectives are met.

Skills and Competencies

Experienced in concept design of automated lean assembly manufacturing lines
Ability to lead on allocated projects with a budget up to £1 million.
Expert knowledge in continuous improvement methods to improve overall equipment effectiveness (OEE), quality, reduce cost, inefficiencies, and waste.
Skilled in methods engineering, time and motion study and assemble line balancing
Skilled in PFMEA, SPC, MSA, PPAP and VDA 6.3 tools
Skilled in Microsoft Project for planning and resource loading.
Skilled in the use of 2D and 3D CAD systems and manufacturing simulation and modelling packages e.g. AutoCAD, Creo, SolidWorks, DFMEA, visual components etc.
Ability to work in a multi-functional team and to build relationships with peers and effectively communicate complex technical concepts to different audiences and senior stakeholders in simplistic terms.
Team leadership experience in a high paced manufacturing environment.

Qualifications

A BSc/BEng/MEng degree or HND in Manufacturing Systems, Industrial or Mechanical Engineering with over 5 years’ experience in a similar role.
Lean Six sigma Black belt or Green Belt qualified

EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. EEO/Minority/Female/Vets/Disabled

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Senior Project and Design Engineer