Thursday, April 7, 2022

Ford Motors - Industrial Engineering Activities and Jobs



Industrial Engineering - Productivity Improvement - Process Improvement - Product Redesign - Continuous Improvement


Industrial engineering is improvement in various elements of engineering operations to increase productivity. Along with engineering elements, industrial engineers evaluate and improve many other elements also as they are responsible for productivity and cost of items produced in a process. Through assignments of improving productivity and efficiency of information technology and software engineering processes, industrial engineers specializing in IT were given responsibility for business processes also. Thus industrial engineers with focus on various branches of engineering provide their services to companies and society to improve various elements of the products and processes on a continuous basis over the product life cycle. They are active in engineering or production-maintenance-service-logistic processes and business processes.

Productivity improvement always focuses on quality and flexibility issues as productivity improvement should not lead to any deterioration in quality or flexibility. Delivery and cost are always at the core of industrial engineering. Thus when QFCD paradigm came, that is attention to quality, flexibility, cost and delivery became prominent, many industrial engineers were given the responsibility of managing this function of continuous improvement.


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Focus Areas of Industrial Engineering - Brief Explanation


Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.
Productivity Science - Determinants of Productivity

Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.
Product Industrial Engineering


Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.
Process Industrial Engineering

Industrial Engineering Optimization: Optimizing industrial engineering solutions created in Product Industrial Engineering and Process Industrial Engineering.
Operations Research - An Efficiency Improvement Tool for Industrial Engineers

Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.
Statistics and Industrial Engineering

Industrial Engineering Economics: Economic analysis of industrial engineering projects.
Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers


Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.
Motion Study - Human Effort Industrial Engineering

Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.
Industrial Engineering Data and Measurements

Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.
Productivity Management

Applied Industrial Engineering: Application of industrial engineering in new technologies, existing technologies, engineering business and industrial processes and other areas.
Applied Industrial Engineering - Process Steps

How many Industrial Engineers can a Company Employ for Cost Reduction?

For $100 million cost, there can be one MS IE and 6 BSIEs.
https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html

Industrial Engineering - Lean Manufacturing - Parent - Child Relationship


Ford - Industrial Engineers





Narendran Sekar

Industrial Engineer at Ford Motor Company

Cincinnati, Ohio Area

Eperience
Ford Motor Company (Optimal Engineering, Inc.)
Industrial Engineer | Ford Powertrain Operations
Since Sep 2018
Location: Sharonville, Ohio
• Develop Capacity strategy for the current, future and retool powertrain programs.
• Support Process Audits, Resource allocation, Program Volume and Operational patterns.
Track IE efficiency metrics (Flow sheets, DOT maps, capacity and cost studies).
• Perform Time Studies, Work assessments- MODAPTS to determine capability.
• Supported launch- Workstation readiness, Assessments to improve machine uptime & line speed.
• Knowledgeable in Ford IE documentation (GSPAS, Labor Glide path, Program 1-Pager, Operator Instruction Sheet /Job Safety Assessment, Ergo CS).
• Work with UAW Local 863 on substantiating utilization with standard time data.

Improvement Projects
• Mapped valve-body flow lines in Value stream mapping, identified and eliminated bottlenecks using line-balancing applications. Eliminated overtime, off standard headcounts accounting to $250,000 savings.
• Deployed Line balancing & capacity expansion on Weld Lines to boost productivity & cross flexing.
• Developed an improved part availability strategy on Carrier Assembly lines to reduce Temporary Lay Off (TLO) and downtime.
Ford Motor Company Recognition Award for budget saving in second quarter of 2019.
• Reviewed factory plans and layout schematics for ergonomics projects.

Education
University of Michigan-Dearborn

Master of Science - MS Industrial and Systems Engineering
2016 – 2018

Activities and Societies: Society of Manufacturing Engineers (SME)

Production and Operations Engineering
Total Quality Management and Six sigma
Design and Analysis of Experiments
Human Factors and Ergonomics
Vehicle Packaging and Ergonomics
User Interface design- HMI/HCI
Business Process Integration using SAP ERP system
Program and Project Management
Engineering Probability & Statistics


Pondicherry University

Bachelor of Engineering Technology Field Of Study: Mechanical Engineering
2011 – 2015

Mechanical Design Engineering
Plant Operations Engineering
Computer Integrated Advanced Manufacturing Process
Manufacturing and Production Engineering
Operations Research


Licenses & Certifications
INTERNATIONAL MODAPTS ASSOCIATION INC
Basic MODAPTS Practitioner
Nov 2019

Ford Motor Company
GD&T ASME.Y-14.5
May 2019

Ford Motor Company
Value Stream Mapping
Issued date of the certification or license Issued May 2019
https://www.linkedin.com/in/nsekar145/

Ford - Industrial Engineering Activities

Process Industrial Engineering

Study of Robot Assembling Process Using AI Increases Line Speed by 15%.
28 April 2021 

At Ford Transmission Plant in Livonia, Michigan, the station where robots help assemble torque converters now uses a system that uses AI to learn from previous attempts how to wiggle the pieces into place most efficiently. Robot arms wheel around grasping circular pieces of metal, each about the diameter of a dinner plate, from a conveyor and slot them together.

The technology used is from Symbio Robotics that looks at the past attempts to determine which approaches and motions appeared to work best. The technology has sensing and controlling the arms. Toyota and Nissan are using the same tech to improve the efficiency of their production lines.

The technology allows this part of the assembly line to run 15 percent faster, a significant improvement. 
The technology can be used anywhere it’s possible for a computer to learn from feeling how things fit together. There are opportunities for similar applications. The  robots that help assemble, weld, and paint vehicles are essentially powerful and useful but lack any ability to understand or react to their surroundings. Researchers and inventors are exploring ways for AI to enable robots to perceive and grasp even unfamiliar objects moving along conveyor belts. The Ford application described shows how existing machinery can be further improved by introducing simple sensing and learning capabilities.


BENEFITS TO FORD MOTOR COMPANY DUE TO SIX SIGMA IMPLEMENTATION


Ford Motor Company implemented Six Sigma in late 1990s calling it ‘Consumer-driven Six Sigma‘.

Ford was the first major automobile company in the world to adopt the Six Sigma initiative in a big way. According to 2003 Annual Report, the quality improvement and waste elimination methodology, has had an increasingly dramatic impact on the  operation of the enterprise. Since the inception of Customer Driven Six Sigma , Ford has completed more than 9,500 projects savings $1.7 billion  worldwide, including $731 million in 2003.
https://www.henryharvin.com/blog/six-sigma-implementation-its-benefits-in-ford-motor-company-2/

Nov 2019
Ford Motor Company is experimenting with 3D knitting technology that will allow the automaker to construct any seat cover in only an hour.

As well as offering greater design flexibility, 3D knitting reduces production steps and creates less waste by removing the requirement to cut and sew together various fabrics and pieces. The 3D knitting machines create covers without any stitching and can use different yarns, such as polyester, wool, silk, carbon fibre, and even recycled materials.
https://media.ford.com/content/fordmedia/feu/en/news/2019/11/11/3d-knitted-car-seat-covers-could-offer-infinite-personalisation-.html


Minimum Quantity Lubrication (MQL) in Automotive Powertrain Machining in Ford

The primary benefits from MQL include cost reduction that includes reduction in energy consumption, improvement in environment, and more effective chip recycling.

Ford began investigating alternatives to conventional flood coolant machining technology for aluminum materials in the 1990s through a collaborative project seeking to completely eliminate coolants with an aim towards completely dry machining of aluminum. Many machining operations for ferrous components were already dry.  The project was carried out through extensive laboratory trials and a series of small-scale production pilots in early 2000s

Ford began applying MQL to aluminum transmission components in 2005, and by 2008 had over 200 MQL machining centers in operation machining aluminum transmission cases, torque converter housings, and valve bodies at two plants in North America. MQL machining became Ford’s current standard machining method for these components, and is being implemented in new high-volume
machining lines globally. Ford began machining aluminum engine heads and cast iron engine blocks  in 2011. MQL is now the primarily standard method for machining cast iron engine blocks and aluminum engine blocks and heads. For some specialized operations still wet machining is used . MQL machining modules are being installed in plants in new locations like Brazil and China.

Ford is making effort to extend MQL machining to additional components like CGI engine block machining, thermally sprayed engine bore machining, and aluminum deep hole drilling. There are technical challenges and the research community and engineering community are involved in finding solutions and extend MQL to new areas of application.

Source:
Minimum Quantity Lubrication (MQL) in Automotive Powertrain Machining
Bruce L. Tai, David A. Stephenson, Richard J. Furness, Albert J. Shih
6th CIRP International Conference on High Performance Cutting, HPC2014
Procedia CIRP 14 ( 2014 ) 523 – 528
doi: 10.1016/j.procir.2014.03.044


Ford - Industrial Engineering  Jobs - Advertisement

Apply now - 6.4.2022

Industrial Engineering Specialist in Flat Rock, Michigan

57661BR

Job Title: Industrial Engineering Specialist


Job Description & Qualifications:



As part of our Manufacturing team, you’ll help build the world-class, state-of-the-art smart vehicles the world expects from us. Within our plants around the world, we’re constantly developing new technologies and processes to further increase our efficiency. That means we’re continually seeking diligent, driven performers who think creatively to help us find better and more efficient ways to manufacture our vehicles.

What you’ll be able to do:

You will play a key role in advancing our manufacturing capabilities as you lead industrial engineers in supporting the development of productivity proposals (e.g., rebalances, OLOT reduction, efficiency improvements, etc.). This position will involve driving important workstation optimization and ergonomics improvement initiatives. You will:

Implement engineering changes for workstations and allocations

Supervise/mentor industrial engineers with time study schedules (e.g., MODAPTS)

Collaborate with union/works council and Health & Safety to settle disputes and ergonomic issues

Lead headcount cost savings projects

Supervise monthly tracking of progress in VPOS

Lead cycle line layout

Supervise planning for mix and line speed changes

Manage departmental rolls analysis for weekly workforce meeting

Ensure accurate labor staffing and strategy

Lead future model labor development

Assist Production and Quality as needed

Uphold plant processes through strict adherence to the Quality Operating System

Serve as resource for plant industrial engineer training/assistance

The minimum requirements we seek:

Bachelor's degree in Industrial Engineering

2+ years of experience working in a manufacturing environment

Our Preferred Requirements:

One or more years of experience with MS Office (to include Word, Excel, Outlook and PowerPoint)

Ability to quickly resolve issues through route cause analysis

Validated ability to maintain a customer centric focus

Results driven with excellent organizational and prioritization skills

Demonstrated success mediating union relations situations

Shown success acting as a strong and confident technical mentor

Exceptional communication and leadership abilities

MODAPS Certification





For information on Ford’s salary and benefits, please visit:

https://clicktime.symantec.com/34jag92XUFJYHaNge9RMLCD7Vc?u=https%3A%2F%2Fcorporate.ford.com%2Fcontent%2Fdam%2Fcorporate%2Fus%2Fen-us%2Fdocuments%2Fcareers%2F2021-benefits-and-comp-GSR-sal-plan-1.pdf



Auto req ID: 57661BR

Company:Ford Motor Company

Function:Manufacturing

Skill Team:Manufacturing Plants (MFG)

Sub-Component:Plants

State:Michigan

Location: Flat Rock


Supplemental Industrial Engineering Specialist - KTP
Ford Motor Company  Louisville, KY On-site 
Dec 2021

We’re seeking a diligent, detail-driven professional to provide vital expertise in support of our manufacturing process engineering activities. We’re looking to you to help us optimize our efforts in safety, quality and productivity. This involves applying engineering principles and analytical techniques to advance continuous improvement of manufacturing processes and products. You will:
Drive development and/or installation of direct and indirect labor standards and methods. Track labor, efficient manpower utilization and line balancing.
Conduct Job Ergonomics evaluations.
Analyze problem process constraints and conduct equipment cycle time analysis.
Recommend most efficient distribution of manpower and review daily employee manpower, analyze plant methods and standards.
Prepare or direct the preparation of cost estimates of new or revised methods and standards.
Review proposed changes in plant layout, processes, material handling, routing, etc.
Analyze production and non-production operations to determine those requiring study and develop new or improved methods and standards.
Conduct time and motion/MODAPTS studies and review employee proposals and suggestions.
Develop cycle line layouts for current and future models using ACAD. Lead job methodization and process allocations.
Coordinate engineering changes and planning. Conduct value stream mapping and process audits.
Develop cost saving project proposals and write projects as required.
Interface with Production Supervision and the UAW to settle job disputes.
Assist production in planning labor allocations for mix and line speed changes.
The Minimum Requirements We Seek
Bachelor’s Degree in Engineering field
1+ years’ experience in Industrial Engineering (co-op/internships may be considered)
1+ years’ experience with Microsoft Office (Word/Excel/PowerPoint/Outlook)
Our Preferred Requirements
Exceptional communication skills
Lean Manufacturing and Six Sigma experience
MODAPTS Certification
GSPAS knowledge
Outstanding leadership, interpersonal, and teambuilding skills

Cost Reduction


March 2020

Cost Estimation Analyst
Company Name Ford Motor Company Company Location Ciudad de México, Distrito Federal, México
This job is no longer accepting applications

The Role:

The Cost Estimation Analyst (CE) is responsible for understanding and analyzing manufacturing processes to estimate the price per piece based on the analysis and understanding of the designs and processes necessary to develop the different components of Ford cars.


Your impact:

Generate Estimates for 2-sided Teardown (Competitor vs. Ford Vehicles) or 1 side Teardown based on the physical parts.
Support Engineering team to figure out the Cost Difference based on the design variances.
Support Engineering team to figure out the opportunities on Design Optimization.
Generate Estimates for the commodities by reviewing sketches, blueprints, parts and functional information.
Support Buyer on Gap Analysis to figure out cost reduction opportunities.
Support Buyer to negotiate with suppliers
Support Buyers to formulate the Commercial Strategy.
Support Engineer to formulate Design Strategy.
Generate Piece Price & Tooling Estimates for Key milestones based on the Design info from Engineering team to support Program Target Setting.
Support Engineering and Purchasing on negotiation with suppliers to deliver program target.
Ad Hoc Requests from Cost Estimating Management.

What you will need:

Industrial Engineering, Mechatronic Engineering, Mechanic Engineering or similar (No Industrial Design, or Civil Engineering). Master Degree is a plus.
English 90% (able to sustain commercial and manufacturing conversations).
3 years of experience in manufacturing areas like “Stamping” or “Plastic Injection”.
Good Technical knowledge on Manufacturing Processes and Tooling Processes; Good Data Analysis skills, Microsoft Office tools (Excel, Word, PowerPoint, Access, etc.).
Good Communication Skills, Proactive attitude, Good problem solving capabilities, Ability to work in Teams.
Negotiation skills, communication skills, proactivity, dynamism.
Software: CATIA, 3D Visual.

https://www.linkedin.com/jobs/view/cost-estimation-analysit-at-ford-motor-company-1768300518/


Chassis Material Cost Reduction Product Engineer
Company NameFord Motor Company Company Location Dearborn, MI, US
This job is no longer accepting applications

Job Description

Position Overview:

Ford Product Development is utilizing Design Thinking & User Experience methods to deliver breakthrough products and services that will delight our customers. Our employees are laser-focused on bringing innovative, exciting, and sustainable ideas to life. From autonomy and electrification, to smart mobility technologies, our Product Development teams around the world are working together with excitement to make smart vehicles for a smart world.

Responsibilities
Identify Best-In-Class Designs using input from core team (efficient component designs).
Drive application team to identify, develop, design and validate new ideas (provide support where required to help team achieve goals).
Ensure PD alignment and ownership of idea approval, validation and implementation (participate in PD Manager Design Reviews)
Manage Bill-of-Material review for triage of existing and new ideas
Deep dive all launch fixes/cost-increases to improve value.
Support Supplier Engagement, VSM, Value Chain and other initiatives to enable target delivery.
Represent Chassis as primary interface to the Ford Assembly Plant team - drive VO approval and support change scheduling and plant trials in a timely manner.
Maintain cost reduction roadmap and update progress report for the Chassis Engineering Chunks.
Manage updates and tracking of the Cost Reduction Idea Database (CRID).
Consult WERS and CMMS to monitor progress of cost reduction actions. Escalate issues as required.
Support audit process to ensure prompt realization of savings.
Engage global engineering, purchasing and finance regularly to determine next steps & actions to keep ideas on track
Develop data tools that keep teams focused on achieving our cost saving targets and timely delivery.
Use data analytic tools to identify cost saving opportunities in released designs
Develop special reports and analysis for management reviews and investigations
Facilitate Benchmarking and Costed Events
Facilitate Line Walk Events at Assembly Plants.
Facilitate Gap Week activities including planning and team support.

Basic Qualifications
Bachelor of Science in Engineering
2+ years automotive experience involved in cost reduction activities

Preferred Qualifications
Knowledge of Chassis components and systems
Knowledge of the Ford Material Cost Reduction and Design and Release Processes
Experience using WERS, CRID, CMMS and Teamcenter tools
Expert in MS Office (Excel/Word/Powerpoint) and Access
Excellent verbal and written communication skills
Excellent organizational skills and ability to multitask

Join our team as we create tomorrow! We believe in putting people first, working together, and facing challenges head-on, because we're Built Ford Tough. We're one team striving to make people's lives better while creating value, delivering excellence and ultimately going for thewin.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States on a permanent basis. Verification of employment eligibility will be required at the time of hire. Visa sponsorship is not available for this position.
https://www.linkedin.com/jobs/view/chassis-material-cost-reduction-product-engineer-at-ford-motor-company-1425798354/





Fujitsu - Industrial Engineering Activities and Jobs


Austin Ware
Industrial Engineer II at Fujitsu Network Communications
Dallas/Fort Worth Area
https://www.linkedin.com/in/austin-ware-75574226/

Garrett Foster
Industrial Engineer at Fujitsu Network Communications
Dallas, Texas
Industrial Engineer II
Since: Nov 2018 – Present

Education
Kansas State University
Degree Name: Industrial Systems and Manufacturing Engineering
2012 – 2017
https://www.linkedin.com/in/garrett-foster-a46b6a127/


Donnie Sketchley
Industrial Engineer II at Fujitsu Network Communications
Overland Park, Kansas

Experience
Fujitsu Network Communications
Industrial Engineer II
Since: May 2015
Location: Richardson, TX

Production Control Responsibilities:
• Manage the production plan for multiple product families, meeting aggressive on time delivery requirements and optimizing manufacturing efficiency.
• Oversee design changes and component cutovers to minimize scrap, maintain revision control, and ensure compliance with ISO 9001 standards.
• Monitor key performance indicators including budget attainmentcost reduction initiatives, and manufacturing plan efficiency.
 Led an improvement project to implement standardized work and Lean Manufacturing principles in the FNC warehouse, reducing overtime by 5% annually.

Education
Kansas State University
Kansas State University
Degree Name:BS/MS; Field Of Study:Industrial and Manufacturing Systems Engineering
Dates attended or expected graduation2010 – 2015
https://www.linkedin.com/in/donnie-sketchley-70068358/


Industrial engineers are employed and productivity improvement and cost reduction are practiced in many companies using Industrial engineering philosophy, principles, methods, techniques and tools.

Index to Industrial Engineering Practice in Top Global Manufacturing Companies - Top 100



Updated on 2 May 2020

First published on 7 April 2020

2 comments:

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