Engineering Assistant

Description

Position at Sumitomo Electric Lightwave Corp.

Job Summary  The Production process follows documented procedures to inspect product prior to shipment to the next step of manufacturing or to the customer.  Each step of the production processes is comprised of multiple processes requiring careful attention to detail and accuracy in maintaining parameter specifications to assure product is manufactured with the goal of zero defects.  These processes are performed in  a manufacturing environment. The Engineering Assistant works with the area process engineer to assure the equipment is in proper operating condition by troubleshooting and correcting process and production problems which exceed the written problem-resolution standards.  Work is self-generated by analyzing quality of product output and the detailed process and trouble reports; However, the engineering assistant works with the process engineer in developing improvements of the process and equipment. Trends are noted and timely recommendations made as to corrective action to take.  In addition to analyzing and correcting problems, the position evaluates and sets up new equipment and prepares documentation for the production staff which clearly outlines the equipment set-up to minimize errors when creating and maintaining indication sheets.  The position also trains others in how to use the new equipment/process and experiments to improve process yields and to reduce manufacturing costs.  Further, the position certifies the staff in proper operation of equipment, creates reports on process and assists in establishing product specifications.  The position serves as a liaison between the Process Engineering staff and Production staff to meet output and quality goals.   Job Duties and Responsibilities  A.  Essential Functions  Production and Technical Responsibilities 

• Analyze daily product and computer-generated process reports to identify and resolve problems with the equipment or the product to prevent major problems from occurring.  Inspect dies, tooling and other machine parts to uncover any abnormalities with the equipment.
• Evaluate processes on an ongoing basis to identify potential problem areas and recommend design changes. Investigate and implement new equipment and machine designs to expedite production, improve safety and reduce process time.  Isolate problem area(s) and issue maintenance work requests for equipment repairs.

1.3  Evaluate the cable produced for compliance with product specifications including data on the thickness of the core lumps and fiber length and adjust process conditions accordingly to improve output and efficiency. 1.4  Set-up, calibrate and assemble equipment for a new product, test run or new process to establish parameters and to assure a consistent quality process.  Assure proper oxygen and nitrogen flows, appropriate tolerances in the ribbon process, and overall quality condition of the fiber.  Inspect all equipment, controls and safety features to assure proper and safe operating condition prior to the beginning of the inking and ribbon processes. 1.5  Order, receive, test and install machine parts and determine usage rates for all new parts.  Meet with vendors to discuss new equipment and tool product lines for suitability to the cabling processes. 1.6  Communicate with production staff and design, product and process engineering staff to identify and resolve problems and to train in new processes and specifications. 1.7  Help enforce operating instructions to production staff.  Distribute and communicate controlled documents including indication sheets, one-point standards, temporary procedure instructions (TPI) and engineering control notices (ECN) to maintain the ISO certification.  Write operation and training manual updates as changes occur. 1.8  Report all required information into the computerized data collection system for quality, quantity,     status.

• Provide training to all assigned staff.
•  Work and report to the area process engineer to improve the process or design of the product.  When changing the product design, the engineering assistant and process engineer will work directly with product design to assure all design criteria meet the required industrial standards.

  Quality Responsibilities  2.1  Check processes for adherence with established quality parameters and process specifications.  Assure that indication sheets (~700) are correct and correspond to their respective design sheets. 2.2  Regularly monitor and adjust the inking and ribbon processes to assure proper coloring, tolerances and flow to create a quality product During the process, evaluate the equipment and the product for defects and adjust process to minimize problems.   Reporting and Paperwork Responsibilities 3.1  Assist documentation outlining product and process problems and corrective actions.  Compile data on trends in yield, output, and scrap and related action items for historical perspective and for determining adjustments and preventive measures. 3.2  Assist all trial data and EPO's run.  The trial and EPO reports are to be sent to the corresponding design staff and manufacturing staff for up to date technical information exchange.   Responsibility for the Work of Others  4.1 Participate as a member of the training/certification team for the responsible area processes Coach production staff as needed on proper work procedures. 4.3  Work as a contributing member of the Process Improvement Team Responsibility for the Safety of Others 5.1  Observe the work area and work practices to identify any unsafe conditions or practices.  Recommend changes to machines and the use of different tools or equipment for safer operation. 5.2  Intervene when problems are noted to promote and assure safety of all. 5.3  Practice and monitor appropriate safety practices to prevent injury to self and others. 5.4  Read the Safety Data Sheets to learn about any hazardous materials used.   B.   Additional Responsibilities 1.1  Perform other related duties as assigned by the area process engineer. 1.2  Participate in Model Shop Activities(5S).   C.  Instruments, Tools, Machines or Equipment Used

• Area production equipment and related equipment which may be used in other areas of the manufacturing facility.
• Precision measuring instruments to measure and verify the exact length and diameter of the fiber and/or tubes/jacketed
• Computer system for data compilation and report generation and to issue revised designs and operating instructions.
• Various hand tools to disassemble, assemble and adjust equipment, tension and pressures.
• Calipers, pyrometers, manometers and various other gauges and hand tools.
• Develop design skills by learning CAD, thereby helping to make documented changes to floor equipment.

Knowledge, Skills and Abilities A.  Minimum Learned Skills and Abilities Required  1.1  Ability to quickly analyze production problems and determine which changes to make to maintain     product specifications and production schedules. 1.2  Comprehensive knowledge of the mechanical, electrical and fiber optic systems and operations including the ability to read and interpret/translate blueprints, diagrams, flow charts and engineering reports. B.   Minimum Learned Skills and Abilities Required (Cont.)

• Ability to use arithmetic and math formulas including fractions, decimals and basic statistical analysis.
• Ability to use basic trigonometry and analytical geometry.

1.4  Thorough knowledge of appropriate safety procedures relative to the operational processes. 1.5  Ability to use the computer for data compilation and analysis and for report generation and design changes. 1.6  Ability to develop and communicate written standard operating procedures and troubleshooting guidelines for use by the production staff. 1.7  Ability to respond to alarms and other interruptions at the same time keeping the work in process     flowing as smoothly as possible to meet production goals. 1.8  Ability to communicate clearly in instructing employees in correct and safe operating procedures.

• Willingness to work as a committed team member.
•  Willingness to learn basic material science (processing related) of the material used in the specific area of work.

  C.  Minimum Education Requirements  1.1  Completion of high school course work and graduation from high school. 1.2  One year of technical training including equipment and process maintenance or its equivalent years on the job training progressing through all the steps associated with the processes in the specific area of work.  

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