NPI Engineer

Job Summary: As an NPI Engineer, you will play a pivotal role in the seamless introduction of new products into manufacturing by ensuring early alignment between design and production. You will lead efforts to optimize manufacturing processes, improve yields, enhance product quality, and reduce time-to-market. This role requires collaboration with cross-functional teams, application of advanced problem-solving techniques, and implementation of preventive measures to guarantee high product standards and customer satisfaction. Additionally, you will be responsible for key quality assurance tools such as DFMEA, PFMEA, Control Plans, and other continuous improvement methodologies.

Key Responsibilities:

1. Early Design-to-Manufacturing Alignment:

o Collaborate with design and manufacturing teams to address production constraints early in product development, minimizing design revisions and ensuring smooth transitions from concept to production.

o Use tools such as Design Failure Mode and Effects Analysis (DFMEA) to proactively identify potential design risks and drive corrective actions before production starts.

2. Yield Improvement and Manufacturing Efficiency:

o Co-lead the NPI team in refining manufacturing processes to increase production yields and improve product quality.

o Develop and implement Process Failure Mode and Effects Analysis (PFMEA) and Control Plans to prevent production failures and optimize manufacturing efficiency.

o Integrate Poka Yoke (error-proofing) techniques to prevent mistakes and ensure consistent quality output.

3. Enhanced Product Quality and Customer Satisfaction:

o Work with cross-functional teams to ensure products meet the highest quality standards by leveraging GFT’s manufacturing expertise and Hasbro’s product development insights.

o Conduct root cause analysis and failure analysis on production issues, using methods such as 8D reporting to implement effective corrective and preventive actions.

o Ensure continuous quality improvement and customer satisfaction through enhanced process control and product reliability.

4. Faster Time-to-Market:

o Streamline the NPI process by coordinating product testing, documentation, and operator training, reducing production delays and ramp-up times.

o Develop comprehensive process flows and Control Plans that outline every step of production, ensuring smooth operations and faster time-to-market.

5. Shared Knowledge and Best Practices:

o Share best practices in product development and manufacturing with both Hasbro and GFT teams, fostering a culture of continuous improvement and operational excellence.

o Provide training and support to operators and team members on new processes, quality assurance methods, and preventive maintenance measures.

6. Cost-Effective and Sustainable Production:

o Collaborate with design and manufacturing teams to reduce waste and ensure cost-effective production that meets sustainability goals.

o Ensure readiness of process documentation, including Control Plans, Process Flows, and other key quality tools, to streamline manufacturing and reduce costs.

7. Failure Analysis and Corrective Actions:

o Conduct in-depth failure analysis of production issues and develop effective solutions to prevent recurrence.

o Lead 8D problem-solving teams to address significant production challenges, ensuring that corrective actions are implemented and verified.

8. Training and Continuous Improvement:

o Develop and deliver training programs for operators and production staff to ensure they understand process changes, quality standards, and preventive measures.

o Promote a culture of continuous improvement by implementing best practices in Lean manufacturing, Six Sigma, and process optimization.

Qualifications:

• Bachelor’s degree in Engineering (Mechanical, Electrical, Industrial, or related fields).

• 3-5 years of experience in New Product Introduction (NPI), manufacturing engineering, or product development.

• Hands-on experience with DFMEA, PFMEA, Control Plans, Process Flows, and 8D report generation.

• Proficient in Poka Yoke implementation and failure analysis techniques.

• Strong knowledge of manufacturing processes, design-for-manufacturing principles, and yield improvement strategies.

• Ability to lead cross-functional teams and manage NPI processes from concept to production.

• Excellent problem-solving, communication, and project management skills.

• Experience with Lean, Six Sigma, or other process improvement methodologies.

• Knowledge of sustainable manufacturing practices is a plus.

• Language: Mandarin & English

Preferred Qualifications:

• Experience in the consumer products or toy manufacturing industry.

• Proficiency in advanced quality tools and statistical analysis software.