General Summary: Manage and lead the Maintenance department functions in accordance with company policies, manufacturing standards and methods, product requirements, quality standards and production schedules to ensure safety, quality, positive work environment, customer requirements, and manufacturing needs are met through the Toyota Production System (TPS) philosophy. Coordinates maintenance activities to support productivity improvement and cost reduction.
Essential Job Functions:- Direct maintenance activities on all production equipment, facilities and utility systems to provide a reliable production platform.
- Specify, install, and commission all new equipment.
- Develop and implement a predictive and preventative maintenance program in conjunction with production management to ensure operability of all plant production equipment facilities.
- Oversees spare parts control program.
- Provide direction and motivation to group leaders and supervisors focusing on safety, quality, efficiency, cost, and morale.
- Direct and coordinate activities of team members engaged in repair, maintenance, and installation of machines, tools, and equipment to ensure continuous production operation.
- Direct and control activities of team members engaged in maintenance of the building grounds and utility systems of the plant.
- Lead Maintenance supervision in utilizing TPS techniques.
- Learn, implement, and teach TPS techniques to all Maintenance team members.
- Coordinate standardization of processes/methods.
- Lead identification of maintenance problems and eliminate waste.
- Develops and monitors a Maintenance continuous improvement system.
- Develop cost reductions within the Maintenance department.
- Develop and manage annual plan, budget, and Key Performance Indicators (KPI), operating efficiency, and cost control.
- Ensure Maintenance hoshin goals are met and kept on track.
- Plans, reviews, and approves the preparation of budgetary items and capital planning for maintenance department (long and short term.).
- Approves requisitions relating to new and replacement parts, supplies, machinery and equipment for the maintenance areas.
- Review and plan headcount monthly for labor cost control.
- Review and track Maintenance Key Performance Indicators (KPI) including managing machine uptime/downtime and lead problem solving for negative trends or goals not met.
- Generate and report out monthly reports with targets.
- Participates in management discussions and planning sessions to help formulate cost reduction, product improvement, and problem solving activities, and presents operational performance weekly.
- Maintains close surveillance over maintenance operations to ensure scheduled work and material needs; proper use of manpower, skills, equipment, and facilities; proper application of methods and related matters.
- Monitors completion of projects to ensure that safety and quality standards are met.
- Plans and implements effective procedures and policies for maintenance operations to ensure that all equipment tools, facilities, and utilities are in an acceptable state of repair.
- Implement, monitor, and maintain a clean, organized department through 5S activity.
- Develops and maintains positive team member relations centered on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony.
- Provides direction and motivation to team members emphasizing quality, efficiency, productivity, cost reduction, safety and health, and morale.
- Ensures further development of team members through performance evaluation, development of training plans, feedback, coaching, corrective action, and cascade training. Update team member training matrix and schedule any needed training.
- Minimum Qualifications/Requirements:
Education:- Bachelor's Degree in Engineering, Industrial Maintenance, or related field required, or an equivalent combination of education and relevant experience.
Experience:- Greater than 8 years of relevant work experience in a manufacturing environment required, preferably automotive.
- Greater than 4 years of functional leadership experience as supervisor in a manufacturing/maintenance environment required.
Personal/Technical Skills:- Thorough understanding and working knowledge of company product, trade terminology, maintenance and repair operations, manufacturing processes, quality management and control systems and techniques, and equipment and machine operation.
- General understanding and working knowledge of basic engineering principles.
- Working knowledge of automotive industry equipment and production systems.
- General understanding and practical work experience with maintenance systems and processes.
- Practical experience applying Toyota Production System (TPS) principles in an automotive environment.
- Strong knowledge of welding, hydraulics, pneumatics, PLC programming, injection, electrical, and mechanical environment.
- Requires the ability to maintain records and compile data to prepare reports, manuals, and proposals.
- Must be knowledgeable of budgets, costing, scheduling, customer requirements, and preventative maintenance programs.
- Must have knowledge of all safety and environmental regulations.
- Requires the skill of negotiations with external vendors/suppliers and customers.
- Advanced math skills.
- Strong leadership skills and ability.
- Excellent problem solving and people skills.
- Strong organization and planning skills required.
- Ability to work in a fast-paced, multicultural environment.
- Excellent written, verbal, and interpersonal communication skills.
- Ability to plan, supervise, and perform functions of assigned areas.
- Ability to communicate and work well with others in a team environment.
- Ability to function both independently and with good judgment in a team environment.
- Ability to multi-task, handle diversity, and provide leadership through problem resolution.
- Ability to prioritize multiple tasks, work efficiently within time constraints and deadlines, and handle stressful situations in a calm manner.
Language Skills:- Strong verbal and written communication skills in English.
Computer/Software:- Solid working knowledge and experience with Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Lotus Notes/Outlook, Internet, etc.).
- Work Environment/Conditions:
Office: Open Office Environment, moderate noise level.
Plant: Various types of manufacturing environments.
- Standard automotive plant environment with moderate noise level.
- PPE (Personal Protective Equipment) such as safety glasses, steel toe shoes, Kevlar sleeves, hearing protection, etc. may be required in designated engineering, manufacturing, or industrial areas. Personal attire standards may apply.
- Involves moderate or occasional presence of some slightly disagreeable conditions, i.e., cold, dust, heat, odor, etc.
Travel: Must be willing to travel up to 10% of the time.
- Physical Demands:
While performing the duties of this job, the team member is required to talk, hear, and see (with visual acuity). Performance requires mental alertness and sustained attention to needs of the department in terms of workflow, efficiency of operation, machine adjustment, and team member output. Performance requires physical ability to inspect, adjust, and operate equipment. The team member must be capable of walking, sitting, and standing for extended periods of time throughout plant. Occasionally climbing or bending on, under, or near tooling and equipment. May be occasionally required to reach, grasp, and manipulate parts, materials, or equipment. May be occasionally required to lift up to 30 pounds.
