Engineer - Process (Value Stream)

Company Description

Bosch has been present in Malaysia since 1923, represented by Robert Bosch Sdn Bhd, with offices located in Selangor and Penang. In Malaysia, Bosch has diversified businesses in Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The company has three manufacturing plants in Penang providing Car Multimedia, Power Tools and Automotive Steering systems. In 2017, Malaysia contributed sales of RM 615 million (127 million euro) and employed more than 2,800 associates.

Job Description

Job Summary

• Responsible for new product line setup and release.
• Plan, in alignment with TEF1, for MAE and EWAK investments related to workstation and accessories for new and existing lines.
• Perform trial run and buy off for all workstations and accessories of new products.
• Prepare line release documents and perform manufacturing line buy off before Pilot Run or mass production.
• Perform Machine and Process Capability Study to ensure machines and processes meet the capability requirement during mass production. Identify and introduce SPC on certain processes whenever applicable.
• Train and guide trainers, supervisors and maintenance personnel by transferring technical and process know-how.
• Monitor and supervise VSE / FA technician performance to ensure efficiency in value stream improvement activities and processes.
• Responsible for process improvement project in production through time study - VT improvement, direct productivity improvement, ergonomic, workstation, and technology improvement and update Management on the improvement result.
• Support production in achieving the effectiveness, output, FOR and quality target through continuous improvement activity.
• Involve in failure analysis of production FOR and advise failure analyser on the disposition of the rejected parts.
• Lead / Involve in Additional Launch Release (ALR) projects and prepare supplement line release documents for mass production.
• Lead / Provide support for Quality problem resolution through problem solving skills PSS or 8D.
• Responsible to meet the manufacturing line direct productivity (DP) as the Key Performance indicator (KPI)
• Monitor, report of KPI’s in timely manner and establish action plan.
• Specific tasks assigned by the superior as and when necessary.

Job Scope

New Product Introduction

• Responsibility for –Start up projects, MAE, EWAK investments, new product line setup, workstation buyoff and release, etc.
• Support generation of Supplier Requirements Specification (SRS) for purchases of new machines and/or fixtures.
• Actively involves in Product and Process FMEA, prepare PQP and production line release documents before mass production.
• Coordinate PGL Guidelines workshop with PGL coordinators and project team members.
• Lead in Value Stream Design (VSD), Scaling (SCAL), Lean Line Design (LLD) and Flow-orientated Layout (FOL), working closely with PGL coordinator during the new project Project Conception phase. (Kickoff to Project Release)
• Prepare VT calculation and line capacity planning based on the projected new volume for PHEK calculation.
• Perform machine and process capability studies to ensure machine and processes meet the mass production monitoring capability requirement.
• Coordinate sample build in project, prepare pre-pilot and pilot run report and ensure close loop of the action implemented.
• Provide training to trainers, line leaders, supervisors and maintenance personnel on assembly processes of new products by transferring the technical and process know how.
• Support QPV on line stability assessment (Q-VSM) during pre-pilot and pilot build.

Operation Support 

• Responsible for – process improvement activities in production (Time Study - VT improvement, direct productivity improvement, ergonomic, workstation, machine and technology improvement).
• Provide assistance to resolve line FOR issues through failure analysis and advise failure analyzer on the disposition.
• Support cost saving activities and approve alteration change.
• Regular review and update of Production and Quality Instruction (WI), Product Quality Indication (PQI), Control Plan and Process FMEA based on the latest process control in production.
• Ensure ANDI / CR contents are checked before release and implemented correctly.
• Conduct process confirmation to ensure line and process compliances and cycle time according to approved time study (VT) summary.
• Conduct failure investigation with cross-functional team for non-conformance incidents (VQ failure, customer complaint, IDC, FPY, FOR, etc).
• Drive cross functional team for core tools projects, direct productivity improvement and continuous improvement activities.
• Coordinate rework activities for related product issues.
• Lead or participate in PSS/8D for related product quality issues.
• Lead or participate in all relevant audits, including line preparation, documentation and implementation of all corrective actions.
• Involve in Additional Launch Release (ALR) projects and prepare supplement line release documents for mass production.
• Prepare ISIR Evaluation/QZ samples tools.
• Other tasks assigned by the superior as and when necessary.

Qualifications

• Bachelor Degree or equivalent in Mechanical / Electrical & Electronics Engineering.
• Proficiency in spoken and written English and Bahasa Malaysia.
• Minimum of 3 years experience in a manufacturing environment.
• Good in technical report writing and include complete data analysis and action recommendation.
• Experience in new product introduction (NPI), manufacturing activities and documentation (eg: Work Instruction, Control Plan, Process FMEA, Machine and Process Capability Studies, Statistical Process Control – SPC, Time Study (VT), Line Balancing, Setup Plan) is required.
• Knowledge of ISO 9001 Standard, TS16949, IEC/EN60745, 62841, Product safety requirement e.g.UL, CSA is an added advantage.
• Literacy in Microsoft Office applications.
• Familiar with statistical process control methods, MTM-UAS, FMEA and AUTOCAD.
• Able to understand and interpret technical drawing.
• Hand on experience on failure analysis and problem-solving methodology e.g. 5 Why’s, RCA, fault tree analysis etc.
• Ability to apply in-depth knowledge of problem-solving technique in solving Quality issues including risk assessment evaluation.
• Effective communication skills with all levels within the organization, suppliers and customers.
• Proficient in application of DOE, SPC, MSA, FMEA, MTM-UAS and 8D.
• Ability to manage personnel time to ensure completion of assignments.
• Ability to work with minimum supervision and self-motivation.
• Only Malaysian citizens are eligible to apply for this position.

Additional Information

He/she leads the Value Stream Quality team, ensuring that both product and process quality are maintained and continuously improved. He/She is responsible for driving quality excellence by aligning operational practices with customer expectations, regulatory standards, and internal quality requirements. Develop and review the effectiveness of the Quality Management System for Value Stream. Drive for cross-functional teams quality mindset, he/she fosters a collaborative environment that emphasizes proactive quality management and innovation. The role requires a leadership mindset to guide quality initiatives, a hands-on approach to resolving quality challenges, and a strong commitment to cultivating a culture of continuous improvement within the product lifecycles. He/she contributes directly to enhancing product reliability, customer satisfaction, and operational efficiency.