Manufacturing Engineer (EE) (364408)
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Birmingham, AL 35207
Provides technical assistance to manufacturing production, support, processing or quality departments. Monitors production process and support activities in order to maximize efficiency. Recommends solutions to production problems by spending actual time in areas working with production. Works with minimum supervision, but in full cooperation with departmental supervision. Performs occasional supervisory function as required by departmental management. The Manufacturing Engineer establishes production procedures, monitors operations, monitors equipment performance, evaluates materials and supplies to maintain quality production, collects data, performs design work, evaluates problems and develops solutions. Manufacturing Engineers may also be involved in the development, deployment, and maintenance of Manufacturing Execution Systems projects. Manufacturing Engineers assigned to the Machine Shop, Electrical, Melting, Manufacturing Systems and Maintenance Department will have specialized duties in their area of responsibility.
DUCTILE IRON PIPE ENGINEER SPECIFIC RESPONSIBILITIES
Evaluates and develops new methods and procedures to ensure a continued improvement in quality and cost of products. Investigates and implements use of new materials to insure a continued improvement in quality and cost of products using computer and Statistical Process Control (SPC) methods. Studies and improves present processes to insure systems are within statistical control.
Trains personnel in new and standard procedures to ensure continued improvement in quality and quantity in the best environment and safest methods possible.
Studies, evaluates and maintains records on standard staff activities, hazard communications, ergonomics, chain inspections, suggestions, inventory control, etc. Insures O.S.H.A. Federal and State Regulations are met.
Performs supervision role when needed.
Monitors operating supplies and shop materials to maintain quality and avoid delays.
Evaluates quality of work in process and makes recommendations to improve quality. Works with Technical Division to analyze the cause of quality deficiencies and to develop solutions.
Establishes relationships with vendors to develop and maintain adequate sources of supplies and materials.
Assists or solves any problem or emergency at time of occurrence within job boundaries.
Coordinates and assists Maintenance, Construction, Electrical and Engineering personnel on any equipment problems.
Works with other Manufacturing Engineers and the Engineering Department on any changes to improve production and prevent loss.
ELECTRICAL ENGINEER SPECIFIC RESPONSIBILITIES
Designs new and retrofit systems to increase production and reduce delays in AMERICAN production departments. Instructs Electrical Department personnel on how new equipment operates. Submits revised prints of new equipment to the Engineering Department for their records. Investigates new job possibilities.
Coordinates between Electrical Department and Engineering Department on new Engineering Department jobs and technology transfer. Consults with Engineering Department about new purchases.
Monitors and maintains availability of critical parts (PLC’s, Drives, etc.). Procures parts needed for “Rush Repairs”.
Administers scheduled preventative maintenance reports, safety inspection reports, and material safety data sheets. Maintains records of preventative maintenance that have been completed. Follows up on all reports that have not been completed. Prints, reviews, and files monthly and quarterly maintenance reports.
Attends classes, meetings, and seminars for professional development. Teaches classes for Electrical Department personnel on new equipment, technological developments, etc. Designs and teaches electrical maintenance and troubleshooting classes.
Monitors operation, troubleshooting, repair and upgrading of all PC’s used in the Electrical Department.
Provides technical assistance on jobs. Makes minor changes to equipment and prints to ensure smoother operation and higher output.
Draws, modifies, and interprets electrical blueprints. Knows where to locate blueprints for jobs when needed. Reads difficult electrical schematics and blueprints. Knowledgeable of electric motor circuits and the function of various motor components. Trouble shoots electrical breakdowns and minor electronic equipment troubles. Performs bench repair work on electrical equipment (except for motor reworking).
Demonstrates familiarity with all electrical equipment. Knows location of various electrical equipment (motors, controls, etc.) and spare parts. Installs equipment, controls, and motors which includes properly wiring and following through until satisfactorily operational. Determines source of electrical trouble and corrects the problem. Makes adaptations as necessary on electrical equipment to make it work.
Interprets/analyzes CMMS data relating to repeated electrical problems and recommends preventative measures to department head.
Communicates with all vendors to learn about new innovations which may be applicable for solutions to problems. Investigates and evaluates new technologies and techniques.
MACHINE SHOP ENGINEER SPECIFIC RESPONSIBILITIES
Designs equipment and tooling, i.e. jigs, air chucks, boring bars, fixtures, etc. for use in machining.
Oversees the remanufacturing of worn machine tools and/or major machine tool components. Also evaluates new machinery and machining techniques.
Responsible for the redesign of machine tool components during repair.
Performs permanent and/or working drawings of components to be machined in the shop.
Evaluates new projects for Machine Shop which includes producing the Bill of Materials and ordering needed parts and material.
Assists machinists in mathematical needs and proper machining procedures. Communicates with outside vendors in order to control costs of materials and parts.
Attends relevant seminars and training courses in order to increase job knowledge. Assists with the training of Machine Shop personnel.
Completes Return on Investment and Ergonomic forms.
MAINTENANCE ENGINEER SPECIFIC RESPONSIBILITIES
Conducts design modification studies, estimates costs and oversees design and installation of various projects.
Assists Shift Foremen and workbench foremen in component and spare part design modification which includes drawings, fabrication and installation.
Works with the Predictive Maintenance System (Vibration Analysis, etc.) for plant wide equipment condition monitoring and analysis.
Conducts statistical studies on mechanical maintenance and downtime in various areas of the shop to evaluate failure modes for possible design change or preventive maintenance consideration.
Oversees redesign of equipment for Maintenance Department and works on the computerized maintenance management projects.
Writes safe job procedures for various jobs in Maintenance Department.
Maintains hazard communication information and trains all new Maintenance Department employees and summer help in accordance with OSHA’s “Right to Know” Law.
Coordinates engineering efforts of Maintenance Department with other related departments.
MELTING ENGINEER SPECIFIC RESPONSIBILITIES
Knowledgeable of all the product lines that AMERICAN produces and how the Melting Department fits into the over-all production of these products. Knowledgeable of ferrous and nonferrous raw materials used in AMERICAN’s melting processes. Familiar with their chemical and physical properties and how these properties affect melting processes.
Evaluates and recommends improvements to production processes and equipment. Maintains 5S program in areas of responsibility.
Assists support personnel in resolving process and equipment malfunctions.
Assists support departments, Engineering personnel and Melting personnel with specifying, selecting, installing, optimizing, maintaining and repairing the melting systems.
Works with support departments, Engineering personnel and Melting personnel to ensure that emission control systems operate at optimum effectiveness and achieve maximum operation time.
Researches and understands the latest melting system technologies with an emphasis on emission control systems.
Maintains a set of operations manuals for each piece of equipment for each emission system. Develops and makes changes as necessary. This shall include but is not limited to checklists and operational procedures.
Ensures that appropriate operations data is logged and maintained on a daily or as needed basis. Develops operational practices based on this data.
Develops maintenance schedules to ensure optimum operation of the emission control system.
STEEL PIPE ENGINEER SPECIFIC RESPONSIBILITIES
Monitors production runs and assists with shipping and production problems which include mill changes, set-up measurements, and manufacturing control forms. Completes justification reports for the purchase of new equipment or for upgrades by completing investment analysis worksheets. Spends time on the mill lines learning and understanding the operating parameters. Works with mill line personnel in identifying problem areas and investigates ways to improve these areas.
Analyzes process data and material test data. Implements process changes using sound problem solving methodology. Documents all process improvement testing and process changes. Monitors tooling data such as performance life, preventive maintenance cycles, and product scrap or rework amounts.
Reviews customer specifications received from Sales. Records necessary production exceptions and comments. Meets with inspection to discuss and record their comments and exceptions. Reports all comments and exceptions to the Sales department in order to correspond with applicable customer inquiry. Periodically meets with customers to discuss specifications and orders.
Works with Continuous Improvement Teams to improve operations in Steel Pipe. Compiles performance data into Steel Pipe performance evaluation packets.
Aids supervision in conducting safety meetings. Conducts safety testing and departmental hazardous communications training. Files employee accident reports. Aids in creating and maintaining Safe Job procedures, LO/TO documentation, Standard Work procedures, Ergonomics documentation, and ISO procedures.
Works with Engineering, production personnel, and other departments in the determination, installation and startup of new equipment. Develops and documents procedures for new and existing equipment.
Acts as a technical resource for production personnel and performs supervision role when needed.
MANUFACTURING SYSTEMS ENGINEER SPECIFIC RESPONSIBILITIES
Performs Manufacturing Execution Systems (MES) design work which includes the following: A) Develops an understanding of the assigned project goals. B) Helps to evaluate scope of project and clearly defines it with customer’s agreement. C) Confers with other project engineers and internal customers in order to determine the types of equipment and/or devices to be used to perform the desired functions and the degrees of latitude allowed in their design.
Designs new and retrofit MES systems to increase production and reduce delays in AMERICAN production departments. Instructs Manufacturing personnel on how new MES equipment and systems operate. Includes HMI (Human Machine Interface) and Industrial SQL programming. Works with Works Manager’s Office, Engineering, Information Services, and other necessary departments to define parameters and scope of MES projects. Investigates new MES job possibilities.
Helps train co-workers in all aspects of the design process.
Communicates designs for projects to users through meetings, correspondence, papers, reports, etc.
Coordinates between Works Manager’s Office, Electrical, Engineering, and Information Services departments on new Engineering Division projects, new equipment purchases and technology transfer as it relates to the MES system.
Monitors and maintains availability of critical parts (computers, touch screens, thin clients, etc.). Procures parts needed for “Rush Repairs”.
Attends classes, meetings, and seminars for professional development. Teaches classes for Manufacturing personnel on new equipment, technological developments, etc.
Monitors operation, troubleshooting, repair and upgrading of all PC’s used in the MES system. coordinates with Information Services as needed.
Provides technical assistance on jobs. Makes changes to ensure smoother operation and higher output. Includes updates to programming that is used primarily for operation of a piece of equipment or machine. Such programming might or might not be MES data related but resides on a “shared” computer or thin client.
Interprets electrical blueprints. Knows where/how to locate blueprints for jobs when needed. Knowledgeable of MES system infrastructure. Troubleshoots data breakdowns and minor data/corporate network related troubles.
Demonstrates familiarity with all MES systems equipment. Knows location of most/all MES systems equipment (servers, thin clients, PLCs, data network hubs, etc.) and spare parts. Installs MES systems equipment which includes properly wiring and following through until satisfactorily operational. Determines source of trouble and corrects any problems. Makes adaptations as necessary to MES systems equipment and programming to make it work.
Interprets/analyzes pertinent system and applications log files and data relating to repeated data problems and recommends preventative/corrective measures to department head.
Communicates with all vendors to learn about new innovations which may be applicable for solutions to problems. Investigates and evaluates new technologies and techniques.
QA-STEEL PIPE ENGINEER SPECIFIC RESPONSIBILITIES
Reviews customer specifications for exceptions, additional cost that will be incurred, and for skelp ordering information. Reviews skelp orders for accuracy and completeness.
Establishes and manages the training program for ultrasonic, magnetic particle and liquid penetrant technicians.
Trains, examines and certifies ultrasonic, magnetic particle and liquid penetrant technicians.
Continuously manages the work and progress of ultrasonic, magnetic particle and liquid penetrant technicians.
Establishes and maintains operating procedures for effective Non Destructive Testing (NDT) of AMERICAN Cast Iron Pipe Company products, production equipment, and machinery. Assures that the NDT is performed according to applicable specifications.
Becomes very familiar with the products and processes that are being used in order to explain NDT methods to customers. Works with customers and their representatives regarding technical questions about NDT and product quality.
Assists in the establishment of acceptance criteria for NDT.
Develops new testing equipment and techniques as required to meet customer and industry demands. Researches and evaluates new equipment and methods being considered for NDT used by AMERICAN Cast Iron Pipe Company.
Operates various NDT equipment. Performs general maintenance on NDT systems. Also, designs and manufactures some pieces of equipment to be used for NDT.
Conducts correspondence with Sales Department regarding stock skelp and pipe.
Meets with skelp suppliers to discuss product quality and to advise of changing specifications.
Directs and oversees the work with outside companies supplying NDT services to AMERICAN Cast Iron Pipe Company.
Makes technical presentations to internal or external customers as required.
Conducts Steel Pipe research projects as assigned.
Conducts customer tours of the Steel Pipe Mill.
Maintains the documentation and reviews required for compliance with API, Specification Q1 and ISO 9001.
Conducts micro-structural analysis for mill production control.
Assists the Manager of Quality Assurance, Steel Pipe, in the coordination of the quality program.
Evaluates equipment requirements for Steel Pipe-Inspection unit and makes recommendations to purchase required equipment.
Performs spot check on in-line inspection operations.
Investigates field complaints, determines responsibility and recommends solutions.
Conducts regular Safety Meetings and inspections. Maintains current Job Safety Analysis and Hazardous Communication Program.
QUALITY SYSTEMS & COMPLIANCE ENGINEER SPECIFIC RESPONSIBILITIES
Coordinates ISO-9001 Internal Audits. Serves as the Company’s lead internal auditor.
Conducts and monitors the radiation protection program at AMERICAN to comply with Alabama Public Health and NCR regulations. Serves as the Company’s radiation safety officer.
Oversees the functions of the Calibration Lab. Evaluates equipment requirements for the Calibration Lab and makes recommendations to purchase required equipment.
Becomes very familiar with AMERICAN products and processes. Works with customers and their representatives regarding technical questions and product quality.
Investigates field issues or returned products involving customer complaints, determines responsibility and recommends solutions.
Makes technical presentations to internal or external customers as required. Develops quality related training programs as required.
Conducts research projects as assigned.
Evaluates and helps establish quality standards for both ADIP and Steel Pipe product lines.
Manages staff through work delegation, performance and adherence to company safety rules.
Maintains records and files pertaining to Quality Assurance.
Supports the activities of the Director Quality Systems & Compliance as well as the ISO 9000 Coordinator.
Promotes company interest to customers, students and other interested groups.
Keeps up-to-date on the latest technological methods and procedures to maintain competitiveness and avoid obsolescence. Pursues continuing personal development and improvement. Attends classes, meetings, and seminars for professional development such as the AMERICAN Leadership Association, American Foundrymen’s Society, etc.
Establishes liaison with other AMERICAN departments and coordinates various activities that require joint effort with other AMERICAN departments.
Manages Personnel and makes decisions in a manner consistent with the Company’s Equal Employment Opportunity/Affirmative Action Policy and Supervisory Training Policy.
Keeps work area clean and orderly. Knows safety rules that apply to the safety of others and to personal safety. Reports malfunction of equipment to proper authority. Performs other work as instructed by supervision.
Serves on project teams when assigned by supervision.
Must exhibit a B.S. Degree in Electrical Engineering from an accredited four-year college or university. Proof of transcript required.
Must exhibit good command of grammar and spelling.
Must exhibit a record of punctuality and good attendance.
Must exhibit the ability to cooperate well with other individuals.
Must exhibit good oral and written communication skills.
Must exhibit an ability to learn. Weight will be given to grades, engineering courses, and related work experiences.
Must be able to perform light outside travel on company business as needed.
Must be physically able to perform the essential functions of the job, with or without reasonable accommodations.
Due to the hazardous nature of the job environment(mobile equipment, overhead cranes, etc.), acceptable levels of vision and hearing are required in order to identify and respond to visual and audible warnings in a safe manner.
Must exhibit a working knowledge of word processing, spreadsheet and database software such as Word, Excel, Access, etc.
Must exhibit the ability to read and interpret complex engineering drawings, specifications and other technical documents.
Must exhibit attention to detail.
Must exhibit the ability to work under stress.
Must exhibit the ability to work with confidential information and maintain confidentiality.
Must exhibit good organizational skills.
Must exhibit the knowledge, skills and ability to perform the job duties.
Must be able to climb and work from high places.
Must exhibit a basic working knowledge of machinery.
Must exhibit a basic working knowledge of electricity and electrical circuits particularly as they apply to shop equipment operations.
Subject to departmental transfer to other engineering positions within the Manufacturing Division.
Must be available for work during off hours, subject to need.
Graduate education or professional certification.
Several years work experience in a manufacturing environment.
Exhibit basic management skills.
Work experience with the application of Statistical Process Control (SPC).
Knowledge of robotic integration and programming.
Knowledge of AMERICAN’s manufacturing processes and products, or similar processes and products.
Exhibit the ability to read and interpret product codes and specifications.
Advanced knowledge and/or substantial work experience with the latest melting system technologies and/or emission control systems.
Prior work experience in electrical engineering, machine shop, metal forming, tooling design, computer science, information technologies or maintenance.
Training and/or experience with personal computer and computer aided designs.
Possess current Professional Engineering License or, if candidate is a recent graduate, Engineer-In-Training Certification.
Advanced knowledge and/or substantial work experience with PLCs and other automated control systems.
Sitting required while at computer, writing, CAD machine, reading manuals, drawing and performing routine desk activities.
Standing required while observing processes in plant, checking equipment, installing equipment, etc. Standing is required on uneven surfaces such as sand, dirt, gravel, concrete, etc.
Walking within various areas of the plant is required. Walking required on surfaces that may be unlevel such as dirt, gravel, sand, concrete, etc.
Climbing stairs is required to access various areas of the plant such as DIP offices, Steel Pipe runs, Foundry Engineer Office, #3 Machine Shop Office, #5 Machine Shop Office, Maintenance Engineer’s Office, Cupola, Contiarc, Maintenance Classroom, etc.
Climbing ladder required to access storage bins, get onto equipment, get onto crane, observe production, inspect material, inspect equipment, access rail car with material, install equipment, etc.
Balancing required while on ladders, equipment, product, etc.
Stooping, kneeling, crouching and/or crawling required to make adjustments on equipment, measure products, measure equipment, install equipment, observe production or support activity, retrieve material or supplies, etc.
Overhead reach required while on ladders and while adjusting or installing equipment. Overhead reach also required to reach supplies or other items on high shelves, etc.
Forward reach required to perform routine desk activities, drawing, installing equipment, adjusting equipment, etc.
Bended reach required to adjust equipment, install equipment, access lower file drawers, pick up materials, product and equipment, etc.
Handling is required for cores, castings, rolling pipe, telephone, hand tools, machinery, equipment, crane, tape measure, etc.
Use of fingers required for keyboard, calculator, drawing, digital phone, measurement tools, writing, etc.
Feeling occasionally required to make fine adjustments on equipment, feel for defects on products(Castings, pipe, tubes, etc.), feel for temperature, etc.
Talking with supervisor, vendor, customers and co-workers is required.
Vision required for safety, drawing, accuracy, adjusting equipment, reading specifications, observing equipment, observing production and processes, computer, etc.
Hearing required for communication and safety.
Lifting up to 100lb core occasionally required, but average lifting is 10lb or less occasionally. Lifting steel pipe samples, parts and other items weighing approximately 20lb is required. Lifting 20lb to 60lb casting samples is required. Lifting/carrying 50lb box of parts or papers is required.
Carrying up to 30lb tooling to Machine Shop occasionally required; carrying records up to 10lb occasionally required. Carrying steel pipe samples, parts and other items weighing approximately 20lb is required. Lifting/carrying 20lb to 60lb casting samples is required.
Pushing and pulling to roll pipe and move castings with a force of up to 50lb required; usually 5lb or less for file drawers. Push/pull is also required to move or install equipment.