Job Summary
1.1 Serves as the primary technical resource for conducting first-level failure analysis on rejected tools, battery packs, and components from production lines, providing timely investigation and technical support to identify manufacturing, process, material, and supplier-related issues.
1.2 Drives systematic root cause analysis and troubleshooting activities in collaboration with Production, Quality, Engineering, and suppliers to resolve product and process failures, improve product reliability, and minimize quality-related losses.
1.3 Responsible for developing, maintaining, and continuously improving failure analysis methodologies, troubleshooting procedures, test methods, and reporting processes. Ensures consistent and standardized execution of failure analysis activities, supports corrective and preventive action implementation, and recommends improvements based on failure trends and best practices.
1.4 Acts as a technical referent for complex failures that cannot be resolved through routine failure analysis methods, providing detailed investigation findings and recommendations to support decision-making and continuous improvement initiatives.
1.5 Responsible for monitoring and analyzing failure data, identifying recurring issues and trends, and supporting improvement projects to enhance quality, yield, productivity, and customer satisfaction.
2.0 Key Responsibilities / Job Scope
2.1.1 Responsible for conducting first-level failure analysis on rejected tools, battery packs, and components from the production line to identify process, material, manufacturing, or supplier related issues that cannot be resolved by Failure Analyzers.
2.1.2 Coordinate measurement and verification activities for dimensional analysis of parts and assemblies to support root cause investigation and problem-solving activities.
2.1.3 Follow up and track the resolution status of supplier-related quality issues, including coordination with Purchasing Quality Engineering (PUQ) and suppliers to ensure timely containment and corrective actions.
2.1.4 Support Value Stream Engineers (VSE) in the preparation, maintenance, and continuous improvement of production documentation, including In-Process Checklists, Production Work Instructions (PWI), Production Quality Indications (PQI), Quality Alerts, and other manufacturing documents.
2.1.5 Develop and maintain rework and sorting instructions for non-conforming products detected during production to ensure proper containment and disposition activities.
2.1.6 Maintain and update PT Packaging System data, including part number setup and barcode configuration, to ensure accurate material identification, traceability, and shipment accuracy.
2.1.7 Support production in achieving Safety, Quality, Delivery, Cost (SQDC), Effectiveness, Output, FOR, and quality targets through problem-solving and continuous improvement activities.
2.1.8 Support and participate in process improvement projects involving value added time (VT) reduction, direct productivity improvement, workstation optimization, ergonomics enhancement, machine improvement, and technology implementation.
2.1.9 Create, validate, and maintain laser marking programs and tester configurations to ensure correct barcode generation, product traceability, and compliance with product requirements.
2.1.10 Monitor production quality performance and failure trends, perform data analysis, and provide recommendations for corrective and preventive actions to reduce defects and improve process capability.
2.1.11 Support engineering trials, process validations, qualification activities, and the implementation of engineering changes to ensure smooth introduction and sustainment of manufacturing processes.
2.1.12 Participate in root cause analysis, 8D investigations, FMEA reviews, and corrective implementation to improve product quality and manufacturing robustness.
2.1.13 Provide technical support and training to production associates on quality requirements, standard work practices, manufacturing documentation, and process controls.
2.1.14 Ensure compliance with manufacturing procedures, quality standards, safety requirements, and company policies while driving standardization and continuous improvement across production processes.
2.2 Ensures compliance and observance of all relevant regulations of Bosch Central Directives, Code of Conduct, Company policies and procedures as well as all country regulatory compliance in fulfilment of legal and contractual obligations applicable for the Company.
• Diploma or equivalent in Mechanical / Electrical & Electronics Engineering
• Proficiency in spoken and written English and Bahasa Malaysia
• 5 years’ working experience in Technician role/Failure analysis.
• Experience working in manufacturing field or handling machines.
• Experience and knowledge in welding process or laser marking process.
• Expert in Microsoft Office applications
• Familiar with statistical process control methods, MTM-UAS, FMEA and AUTOCAD.
• Knowledge of manufacturing processes, production flow, and assembly operations.
• Knowledge of problem-solving methodologies, including Root Cause Analysis (RCA), 5-Why Analysis, Fishbone Diagram, and 8D methodology.
• Knowledge of production quality systems, defect analysis, failure analysis, containment actions, and corrective action implementation.
• Knowledge of engineering documentation, including Production Work Instructions (PWI), Production Quality Indications (PQI), Control Plans, In-Process Checklists, and Quality Alerts.
• Knowledge of statistical and production performance indicators such as FOR, FPY, OEE, productivity, scrap rate, and process capability.
• Knowledge of dimensional measurement techniques and measuring equipment, such as vernier calipers, height gauges, torque measurement devices, and other inspection tools.
• Knowledge of manufacturing systems and software applications, including SAP, barcode systems, traceability systems, and Microsoft Office applications.
• Knowledge of laser marking systems, barcode generation, traceability requirements, and product identification standards.
• Basic knowledge of supplier quality management and supplier complaint handling processes.