Production Rework Technician III

Position Summary:  

The incumbent will perform one of the following functions as their main responsibility: 

Safely perform timely teardown and rebuild non-conforming products on the rear beam axle rework line to meet established quality standards. 

Position Responsibilities: 

Teardown and Rebuild: 

• Perform teardown on non-conforming products. 
• Perform rebuilds of non-conforming products that are reintroduced to assembly line while maintaining quality of components being reused. 
• Perform multiple tooling changeovers of equipment required to complete rebuilds of axles (beam and drive). 
• Support Engineering in analyzing non-conforming products and warranty returns. 
• Perform repairs of customer direct vendor damaged product. 
• Prepare axles for customer service requirements. 
• Safely and effectively operate equipment and material handling devices, such as overhead cranes and lift assists, etc. 
• Operate pneumatic tools, hand tools, presses, electric tools, etc. safely and effectively. 
• Diagnose failure modes and report findings to the appropriate team (assembly, supplier quality, or engineering). 
• Accurately record failure modes and related details such as part #s and serial #s. 
• Accurately document scrap components and reports through the SAP scanning process. 
• Support and perform detailed quality investigations (measurement/visual inspections/root case analysis) on rejects. 
• Perform in process evaluation/checks (poke yoke) and keep records of performed tasks. 
• Perform containment of defective products while cleaning and inspecting components for either reuse or return to assembly. 
• Properly dispose of unsalvageable components based on disposition guides and metal type. 
• Perform preventive maintenance and maintain TPM records daily.  
• Master equipment as necessary. 
• Maintain housekeeping practices in accordance with 5S standards. 
• Participate in continuous improvement efforts (ZFPS) and provide feedback. 
• Perform special projects as requested and related tasks as needed. 
• Perform proper material identification through Special and Non-Conforming Material Handling Processes.  
• Support new and Engineering Change Product Launches. 
• Follow Control Plans, FMEAs, and understand scrap impact to production 
• Set and manually adjust backlash and stretch on axles to meet customer requirements. 
• Evaluate gear contact patterns to verify correct gear mesh. 

Essential Skills and Experience: 

• High School Diploma or GED 
• Understand and ability to apply understanding to Critical Characteristics of operations.  
• Demonstrated ability to define component characteristics (i.e.: machine surface, spline, threads, nick and bump). 
• 4+ years of related experience. 
• Proficiency in applying mathematical calculations to work 
• Demonstrated problem solving skills and ability to root cause and correct deficiencies. 
• Ability to read and follow Standard Work Instructions, Quality Notifications, and Non-Conforming Material Processes. 
• Strong mechanical aptitude 
• Ability to accurately generate/write reports/summaries, and input data into all required systems including Microsoft Office and digital applications 
• Able to fully understand, and utilize understanding of Control Plans, PFMEA, and Process Quality Audits. 
• Ability to read and apply understanding of blueprints and engineering drawings. 
• Ability to read and evaluate dimensional reports. 
•  Strong ability to identify and accurately document component conditions   
• Ability to be certified as a PIV (Powered Industrial Vehicle) operator. 
• Able to effectively use quality tools including micrometers, calipers, indicators, etc. 
• Ability to apply knowledge of ISO 9001, TS16949 and ISO14001 standards and application 
• Ability to be certified in LOTO (Lock out/Tag out)   
• Demonstrated ability to rebuild and set backlash on an axle within quality standards. 
• Product knowledge of axle or gear driven assemblies. 
• Ability to read and understand metric and SAE (Society of Automotive Engineers) measurements.  
• Ability to effectively communicate in all forms (written, oral) and understand work instructions in English 

Preferred Skills and Experience: 

• Associate's degree in automotive technology and/or ASE/State Certified Mechanic. 
• Working knowledge of Lean concepts. 
• Basic SAP Knowledge. 
• Able to read blueprints and/or engineering drawings. 
• Ability to read and evaluate dimensional reports.  
• Basic Knowledge of Digital Documentation applications. 

Physical demands and work environment:

The physical demands and work environment characteristics described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.  Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. 

Physical demands:  While performing the duties of this job, the associate is required to stand for long periods of time, sit occasionally, use hands to finger, handle or feel objects, tools; or controls;  reach with hands and arms; ascend stairs; balance; stoop; kneel, crouch, or crawl; talk or hear taste or smell.  The associate must occasionally lift and /or move 35 - 50 pounds (i.e. manually transporting parts/axles, and/or pushing/pulling carts to designated areas) Specific vision abilities required by the job include close vision, distance vision, peripheral vision, depth perception and the ability to focus. 

Work Environment: While performing the duties of the job, the associate is exposed to a plant atmosphere with a combination of office and manufacturing floor exposure. Will be exposed to Gear Lube (oil), parts and equipment cleaning solutions, etc.