New Product integration at John Deere Seeding Factory
Integrating new product into existing manufacturing processes and workcenters required a keen understanding of current work and a strategic vision for the future. Within a specific budget, it's up to you to recognize integration options and involve the right decision makers to buy-into the change you're making. You also want the new work to be as frustrating-free and if possible, not be a burden to the unionized work force that would be ultimately in charge of making the new product after introduction.
I started out integrating new hydraulic and assembly parts at the beginning and the end of the planter manufacturing line, but quickly specialized in the end of line (EOL) tester. This test workstation was in charge of verifying the planter was assembled correctly and critical hydraulic, pneumatic, and electronic systems were working before it was pulled off the line for final inspection. With the introduction of Deere's revolutionary high speed planting (ExactEmerge and MaxEmerge), I was in charge of making the new upgraded EOL tester ready for both the new advanced planters and the current product. There were many late nights I spent understanding the requirements for both the new products, current and manufacturing operations and programming the EOL tester. I worked with everyone I could to make the best process I was capable of: test stand supplier, quality managers, design engineers, manufacturing Business Unit Leader, operator, and many more. It required team effort but I was ultimately responsible for making it work for the operator. Although it was the most difficult project I ever worked on, it was also satisfying that these efforts paid off in contributing to a 30% reduction in warranty issues related to assembly. Even better was helping our Brazil brothers and sisters with their own product launch a few years later and relay our lessons learned to help shape their own manufacturing process.
John Deere Seeding Factory, Moline, IL 8/2012 - 08/2014 | New Product Manufacturing Engineer I & II
Managed new product integrations, regarding controller programming and functional test stands, culminating in warranty reduction of 30% for new and current products
Developed 80+ assembly and testing process plans and product assembly simulations for new and current product, working with remote cross-funtional teams in Mexico, India & Brazil
Designed and setup new workcenters with torque-connected tools and programmed work instructions for complex assemblies in a lean, fast-paced sub-assembly line
Co-lead the Project Test council for the product line, including multiple factories, focused on quality manufacturing test document and consistency across all product lines at all factories.
Skills
Project management with cross-functional team including design, test, supplier, manufacturing and operations
Collaboration and communication, identifying and involving key stakeholders to ensure success of launch
Advanced manufacturing knowledge and experience, including connected tools, programmed work instructions, sub-assembly lines with assembly lines, electronic programming stations, and functional test stands