Process Development Engineer

Active Dynamics is a progressive OEM supplier that designs, tests, and manufactures unique solutions for multiple systems and multiple industries. This full-service, end-to-end capabilities are paired with a collaborative, creative approach, global reach, and agile structure to offer real-world benefits in terms of turnaround time, cost, service, and customization. We're always growing, always evolving, and always finding new ways to bring meaningful value to our customers and partners.

As a world leader in the design and manufacturing industry, Active Dynamics is seeking an eager and enthusiastic experienced Process Development Engineer to join our successful Toronto team! We are looking for a talent with solid professional skills in the manufacturing industry who can provide superb work experience. This posting is for an existing, immediate vacancy.

The Process Development Engineer is responsible for leading fabrication process development, providing technical expertise and guidance on fabrication processes and lead, executing improvement initiatives, and ensuring that systems and processes are in place to meet and exceed ADG’s quality and production objectives safely and efficiently. 

Duties and Responsibilities:

• Lead the implementation of complete fabrication process for new programs and ECNs to achieve production and quality signoff and flawless launch as per internal and customer timing/deadlines/milestones standards and requirements.
• Review/analyze component/assembly drawings, participate in internal PFD review meetings and provide subject matter expertise/input to produce the part repeatably as per internal and customer standards and requirements while also providing input during quoting phase as required.
• Provide input in tooling design, machine selection & establishment of process parameters.
• Participate in cross functional APQP meetings to provide input in DFM and GDT analysis, PFMEA, control plans, process capability studies, DOE's, poka-yoke, error proof plans, root cause analysis, and lessons learned.
• Coordinate pilot build with prototype development department, document & communicate lessons learned to product/project engineer/process development manager & ensure the lessons learned are effectively carried over to the production process.
• Collaborate with manufacturing engineer responsible for BOM/routing set up after tooling validation & ensure any changes to the process flow are communicated & updated in the system.
• Lead and coordinate all tooling validation sample runs at supplier(s) and at ADG to ensure a successful run at rate milestone completion based on TAKT time, internal AQPQ and customer PPAP requirements and standards.
• Capable of reading and evaluating CMM reports, quality inspection data, capability reports to provide feedback on process (tooling, equipment) changes required to achieve product capability as per internal and customer standards.
• Provide input in evaluating equipment trial runs and buy offs for new equipment and retrofits and ensure run and rate, PPH and essential safety regulations are met per ADG, OHSA, ESA and CSA standards.
• Conduct training for associates on new equipment and processes, monitor progress and ensure timely and effective handover to production and maintenance using ADG standard Machine Handover Checklist.
• Establish machine process parameters for all new programs and continuously monitor to improve and optimize.
• Prepare, release, maintain and update standardized work instructions, operator instructions, job element sheets, troubleshooting guide(s) for process & equipment.
• Provide technical expertise to production to resolve fabrication process capability and quality issues.
• Communicate with Maintenance and/or Operation Manager on tooling problems related to production.
• Review daily shift and quality reports for top process issues. Discuss with Operations manager, Production Supervisor, Lead Hand and/or Process Development Manager to resolve the issues.
• Co-ordinates the implementation of ECN’s (Engineering Change Notices), internally or customer driven.
• Lead process and equipment root cause analysis initiatives and implement solutions to improve and sustain OEE to ADG standards.
• Maintain an open issues matrix for assigned projects and tasks and ensure timely completion as agreed with the direct manager.
• Lead and participate in 8D, 5 Why’s, RCA, CI meetings for customer complaints, failures and provide appropriate input to resolve issues.
• Assist in reviewing program profitability and provide ideas to reduce waste in the value chain by effectively utilizing lean manufacturing principles.
• Work closely with Maintenance/Tooling Manager and skill trades team to increase machine uptime, conduct RCA on equipment issues and follow up on closure.
• Support the implementation of best practices for the department and the development, monitoring, and application of KPI’s (productivity, cost, quality, safety).   
• Other duties as assigned by Management.

• Mechanical Engineering degree/diploma.
• Lean Six Sigma Black Belt or Green Belt desirable.

Qualifications and Experience:

• Minimum (10) years of hands-on experience in a metal fabrication environment, preferably automotive.
• Experience with tube bending process a definite asset.
• Proficient in blueprint reading and interpretation, and operation of tool room and production equipment (grinding, milling, lathe etc.).
• Strong leadership and communication skills.
• Team player who thrives in a fast-paced work environment.
• Excellent mathematical and mechanical aptitude.
• Excellent trouble-shooting skills for fixtures, cutting tools and Tool Room machinery.
• Strategic thinker with the ability to advocate new ideas, cost savings.
• Sound understanding of SQC, SPC, GDT methods and techniques.
• Intermediate level knowledge of 3D CAD modeling including Creo and AutoCAD.
• Intermediate level expertise in MS Office packages (Word, Excel, PowerPoint, OneNote).
• Self-motivated and able to work with minimum supervision.
• Able to work under extreme demands and tight schedules.
• Able to accept directions and change directions as required.
• Excellent English language, communication, and presentation skills (both verbal and written).
• Basic understanding of WHMIS, IMDS, Ergonomics, Healthy and Safety regulations.
• Some travel may be required.

Our team includes members with a wide diversity of cultural and technical backgrounds, ages, and experiences. We understand that your work at Active should support you no matter your current situation, and we offer several benefits to ensure that your work is fulfilling while respecting your work-life balance:

• Competitive compensation and vacation packages based on current industry norms.
• Group health benefits.
• RRSP matching.
• Advancement opportunities and lateral movement based on personal interest and qualification.

We thank all applicants for their interest; however, only those selected for an interview will be contacted. To be considered, candidates must be eligible to work in Canada. 

If you are interested in applying, please send us your resume demonstrating your qualifications, skills, and experience.

We are committed to diversity and inclusion. Active is an equal opportunity employer and qualified candidates will be considered regardless of race, colour, religion, sex, sexual orientation, gender identity, cultural or national background, marital status, disability status, and any other basis protected by Ontario law.

Under the Accessibility for Ontarians with Disabilities Act (AODA), Active Dynamics provides accommodation support throughout the recruitment process upon request. If you require accommodation at any point throughout the recruitment process, please let us know.