Job description

SECURITY AND INTELLIGENT DOCUMENTS

OFFICE OF THE OPERATIONS MANAGER
SECURE PRODUCTIONS

GENERAL ENGINEER, PG-0801-14

INTRODUCTION

This position is located in the Office of the Operations Manager, Security and Intelligent
Documents (SID). The candidate serves as a Manufacturing Process Engineer with a background in process, mechanical, electrical, and/or software/industrial controls. This position requires a hands-on engineering background, engineering design/development experience, and a desire to solve real problems within a high volume manufacturing environment. The candidate must have an excellent analytical and systematic problem solving engineering skill set and an ability to lead others in this process in addition to a demonstrated success in understanding and correcting manufacturing process and equipment issues to ensure product quality is required. As a hands-on engineer/problem solver, you will see your ideas/designs/solutions implemented quickly and the success will have a major impact on the product, factory, and employee morale.

MAJOR DUTIES AND RESPONSIBILITIES

• The candidate will be assigned to "own" and resolve equipment and/or manufacturing process issues and generate a corrective action plan through coordination of pre- and post-operational analysis for U.S. e-Passport and Secure Credential Card Manufacturing.

The candidate first and foremost a hands-on problem solver using strong systematic problem solving skills. These issues may cause production to stop, reduce product quality or increase spoilage for example. They must be resolved efficiently and the candidate will be held accountable for results.

• The candidate is a technical leader of a multi-disciplined, multi person project team to resolve production problems. This team may include resources from various departments such as production, quality, and product development. The candidate may request support from internal departments and outside consultants when required.

• The candidate may design mechanical modifications to Bindery and Press equipment to improve production capacity and throughput, and to decrease waste utilizing "best practice methodologies" such as Overall Equipment Effectiveness (OEE), Statistical

Process Control (SPC) and other methodologies.

• The candidate will verify if new product designs developed by SID are producible. If they are not, the candidate will recommend changes to make the product producible.

Techniques such as design for manufacturability will be used.

• The candidate will create, design, build, and install system to track and report factory metrics such as throughput, line balancing, equipment utilization and downtime, and product spoilage. Report metrics on OEE. The candidate may be asked to resolve problems adversely affecting these metrics by chartering and leading Kaizen events designed to foster employee engagement and sustain Continuous Improvement.

• Charter and lead Six Sigma/A3 projects designed to foster employee engagement and sustain Continuous Improvement.

• Develop and execute test plans to verify solutions have solved defined problems.

• Implement sensor systems (such as inspection technology), equipment, or software improvements and verify results.

• The candidate will develop standard operating procedures for new equipment for the various processes in manufacturing. This will done in conjunction with the operators,

Quality, and maintenance personnel.

• The candidate will participate in new product launches - creating Routers, Bill-of-

Materials, Standard Work documents, and ISO procedures.

• Develop proposals to cost justify programs to improve productivity, quality, and/or efficiency of the manufacturing operations.

• Develop and track project plans including costs, milestones, schedules and resource requirements.

• The candidate will make presentations to peers and senior management regarding project results and performance. This position has high visibility to senior executive levels.

KNOWLEDGE REQUIRED BY THE POSITION

• Possess a background and experience in an engineering discipline such as mechanical, electrical, industrial controls, chemical, or software engineering.

• The candidate will be a hands-on problem solver with strong systematic and analytical problem solving skills and demonstrated experience and capability to solve real time equipment and factory problems. This includes experience in a structured approach to diagnose and establish root cause of problems and corrective actions.

• Knowledge of current manufacturing and/or printing plant methodologies including but not limited to planning, scheduling, quality assurance, complex supply chain management, packaging and distribution operations, performance measurement and metrics, plant safety, workforce selection, hiring, training and development. These may include ISO 9001, Kanban, Six Sigma, Lean manufacturing, Statistical Process Control, and Quality Management methodologies.

• The candidate will have a good understanding and experience in the use of statistics, statistical methods, and design of experiments. This will be used to develop and execute test plans, interpret data, and make recommendations for process improvement.

• Ability to communicate effectively to a wide variety of audiences (e.g., staff, customers, and executives) through oral and written presentations. Ability to communicate proposals, agency viewpoints, business plans, cost/benefit analyses and educational programs to audiences with varied technical and security backgrounds.

• The candidate must have a knowledge of quality systems and inspection technology.

• The candidate will have an understanding and experience in the implementation of various sensor types and use of data for diagnostics and the development of error/recovery and corrective action procedures.

• This candidate must be capable and eager to learn new technical areas outside of their education and prior experience. This is necessary as technology used in the factory is continuously changing.

• The candidate must have an understanding of equipment reliability and maintainability and experience in the use of the metrics associated with it.

• The candidate must have an understanding of process mapping and use for generating as-is and to-be analysis of factory systems.

• The candidate must have knowledge of factory throughput analysis to ensure production requirements are met by existing and new equipment.

• The candidate must understand mechanical and systems design and be amendable to learning CAD system programs.

• The candidate must have a firm understanding and experience in technical project management techniques and tools and the ability to communicate this information to coworkers and management. This understanding and experience will include

development, tracking, and analysis of costs, milestones, schedules, and resource requirements.

SUPERVISORY CONTROLS

The candidate works under the general supervision of the Operations Manager. The supervisor provides general administrative supervision with assignments in terms of broadly defined missions and functions. The candidate has independent responsibility for actions, decisions, and commitments in his/her field of technical authority and expertise. In the standard engineering practice of conducting design and project review, the candidate is responsible for assembling the necessary panel of subject matter experts and/or project teams. The candidate will serve as the team lead in collaboration and implementation of his/her proposed actions. The supervisor reviews completed work for soundness of overall approach and effectiveness.

GUIDELINES

Security and Intelligent Documents is a secure manufacturing facility and as a recognized technical authority, the candidate must exercise considerable judgment in implementing technical or project solutions that may have considerable impact on production processes and the final product. Guidelines consist or recent resolutions provided by the Department of State, general administrative policies and management and organizational theories, Federal laws and regulations, and GPO directives. Because of the evolution of current practices in Secure
Production and GPO's strategic goals, established guidelines may be unavailable or require substantial interpretation. The candidate is recognized as the technical authority in the interpretation of such broad guidelines, and must exercise considerable judgment, analysis, and ingenuity interpreting and adapting guidelines that exist; while developing new and improved concepts or approaches. The ideas, methods and procedures developed may be on the cutting edge of technology and therefore require sound technical judgment and guidance.

COMPLEXITY

Work consists of a variety of complex project management duties requiring many different and unrelated engineering processes and methods for a broad range of activities involving controversial issues. The systems developed for Passport and Secure Credential production span a wide range of technical disciplines including; mechanical, electrical, materials, and software engineering; electro-optics, machine vision, factory automation and control, and disciplines specific to security printing. The work requires innovative and creative problem solving using strong analytical skills to solve unique and one of a kind problems. Delivery of complex systems to cast and schedule (project management) requires a very multifaceted and multi-disciplined individual. In addition, assignments characterized by unusual demand, national emergency, public interest, national security, and economic constraints require the candidate to develop new concepts and revisions to standard methods and techniques.

SCQI'E AND EFFECT

The purpose of this work is to provide expertise in the resolution of a broad range of critical project management and engineering challenges necessary to ensure successful manufacture of the U.S. Passport and other secure Federal credentials critical to the national interest. The candidate serves as an expert advisor and consultant to officials and managers within as well as other engineers, and industry experts outside the GPO, to advise them on these technical and project management issues.

The impact of U.S. Passport manufacturing and other Secure Credential work affects GPO's ability to fulfill the needs of the Department of State, Department of Homeland Security, and in a broader sense, U.S. National Security.

PERSONAL CONTACTS

Personal contacts include a wide range of key technical and mid/senior management personnel throughout the offices of SID and GPO including key technical and sales/marketing individuals and executives of manufacturing concerns in a wide variety of commercial industries. Other contacts include representatives of other Federal agencies, especially the U.S. Department of
State and the U.S. Department of Homeland Security. Contacts also include vendors.

PURPOSE OF CONTACTS

Contacts with internal technical and management personnel is required to acquire and disseminate information on the projects. This would include the Director, Operations Manager,
Division managers as well as key technical personnel. Contacts are for the purpose of coordinating activities, providing leadership and advice, and accomplishing the goals and fulfilling the mission of the U.S. Passport and Secure Credential manufacturing within a Secure
Production Department.

l'l:IYSICAL DEMANDS

The work is generally sedentary in nature.

WORK ENVIRONMENT

The work is primarily performed in an office setting.

Job Type: Full-time

Pay: $69,463.00 - $88,000.00 per year

Benefits:

• 401(k)
• Dental insurance
• Health insurance
• Paid time off
• Vision insurance

Schedule:

• 8 hour shift

Ability to commute/relocate:

• Stennis Space Center, MS 39522: Reliably commute or planning to relocate before starting work (Required)

Experience:

• Engineering Problem Solving: 3 years (Required)
• ISO 9001, Kanban, Six Sigma, Lean Manufacturing: 1 year (Required)

Work Location: Hybrid remote in Stennis Space Center, MS 39522

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