Directs Team Leaders and other Team Members in assigned manufacturing area(s) in the execution of the group’s responsibilities.  Support the manufacturing areas and maintain the overall Toyota Production System with a focus on minimizing down time, increasing productivity, and coordinating preventative maintenance activities.  Manages group as an operational unit and responsible to accomplish company goals and targets in accordance with all company policies, maintenance standards and methods, and standards for safety, quality, productivity, cost reduction, housekeeping, efficiency, training, teamwork, and morale. 

1. Function as a first-line supervisor over team leaders and team members. 
   • Plan and coordinate hiring and placement of team members with his/her Assistant Manager or Manager. Monitor and track staffing conditions, work hours and overtime, job rotation, and absenteeism.
   • Understand, execute, and ensure consistent compliance with all company rules, policies, and practices, and take appropriate corrective action when warranted, in accordance with the terms of the Team Member Handbook.
   • Responsible for managing and appraising team member job performance and recommending corrective action.
   • Develop and maintain positive team member relations centered on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony.
   • Provide direction and motivation to team members emphasizing safety, quality, efficiency, productivity, cost reduction, and morale.
2. Responsible for leading and maintaining the maintenance and repair operations of assigned area, accomplishing department hoshin goals and keeping on task with targets and implementation schedule.
   • Utilize Toyota Production System (TPS) techniques to standardize current/new processes and methods, reduce process variation, identify waste, and methodically eliminate waste.
   • Develop standardized work procedures by designing and/or documenting the best maintenance work sequence for each piece of equipment or tooling.
   • Direct the work of Team Leaders and Team Members by assigning/re-assigning work based on current work situation and production schedules.
   • Direct floor activities through consistent application of Toyota Boshoku Business Practices (TBBP) to ensure all aspects of manufacturing maintenance and repair operations are effective and corrects sub-standard situations.
   • Perform the essential job functions of team leaders or team members as necessary to maintain efficient, stable, and continuous operations.
3. Direct and control maintenance activities on all production equipment, facilities, and utility systems to provide a reliable production platform.
   • Develop predictive and preventive maintenance programs in conjunction with production management to ensure operability of all plant production equipment and facilities.
   • Monitor the Preventive Maintenance (PM) scheduling for completion and performance and evaluate breakdown situations for PM effectiveness.
   • Direct and coordinate activities of team members engaged in repair, maintenance, and installation of machines, tools, and equipment to ensure continuous production operations.
   • Manage and maintain machine uptime/downtime in accordance with departmental and company goals.
   • Coordinate and support maintenance and operations of facilities and utility systems.
   • When needed, obtain part quotations and submit purchase orders for machine, equipment, and tooling repairs.
   • Support spare parts purchases and operation of parts and tooling crib.
   • Research obsolete equipment spare parts and components, design when applicable, and source suitable replacement components or repairs.
   • Responsible for developing maintenance systems that support achievement of company annual plan targets.
4. Utilize knowledge and skills to maintain the highest level of safety, quality and efficiency for production equipment, tooling and facilities.
   • Ensure production equipment, tooling, and facility can maintain the proper flow of parts and materials with good quality and safety. Take corrective action if needed.
   • Partner with the Manufacturing department to initiate investigation and containment activities when a safety or quality problem occurs.
   • Act as a technical problem solving resource in the assigned area by determining the root cause and countermeasure required, especially in the case of equipment-related manufacturing interruptions.
   • Troubleshoot daily safety, machine, equipment, and tooling issues.
   • Be proactive in predicting abnormalities and finding innovative solutions to correct.
   • Evaluate and analyze problems involving machinery and equipment and coordinates repair of tools and machinery. Participate in frequent evaluation of machines, tools, equipment, etc.
5. Lead continuous improvement activity for assigned area.
   • Participate in the setting of Key Performance Indicator (KPI) targets as a method of continuous improvement.
   • Maintain, monitor, and update department and KPI board and graphs, daily, and initiate continuous improvement activities.
   • Initiate, coordinate, and participate in safety, productivity, and cost improvement projects.
   • Lead the implementation of team members’ ideas and suggestions and Management directed initiatives.
   • Lead and audit 5S in designated areas. Maintain a safe working environment for all team members.
6. Ensure compliance with safety regulations, PPE requirements, and company safety policies and procedures.
   • Confirm all work is conducted in a safe manner including the use of job hazard assessments and risk mitigation before starting work.
   • Have thorough understanding of LOTO procedures and ensure all team members follow the policy. Recommend appropriate changes to procedures if needed and be able to make the revised changes and submit them to management and safety for review.
   • Lead, perform, and/or participate in accident investigations, safety audits and related activities.
   • Maintain knowledge of procedures concerning Hazardous Waste, Spill Response, and Plant Security.
   • Monitor safety and health of team members to ensure their well-being.
7. Train and coach team members to maintain productivity and quality standards, including environmental, safety, quality, job performance, setups, trouble shooting, continuous improvement, and maintenance and repair operations.
   • Oversee all training of team members and assign experienced and/or certified trainers to perform new team member training and cross training as needed.
   • Maintain training matrix for team leaders and/or team members, assuring training is effective and corrects sub standard performance.
   • Responsible for multi-skills training to effectively handle breakdown situations.
   • Maintain, plan, and prepare department instruction manuals.
   • Ensure further development of team members through performance evaluation, development of training plans, feedback, coaching, and cascade training.
8. Collect, record, and analyze information while maintaining documentation regarding the activities in the assigned area as defined by company policy, procedure, or practice.
   • Prepare business reports and spread sheets of required data.
   • Maintain specified records, files and logs of department/shift activities such as equipment problems, utility operations, maintenance, repair, etc. (manual and computer) as required. Perform other various administrative duties.
   • Monitor and maintain team member time, attendance, and training records.
9. Communicate frequently with internal contacts on various issues.
   • Through daily communication meetings, keep team members informed on issues relevant to them and encourage two-way communication.
   • Maintain daily and/or frequent communication with upstream and downstream groups/areas and support departments to ensure efficient and stable operations in a team-based environment.
   • Coordinate communications between shifts for assigned area(s).
     
     

Education:

• • High school diploma, GED, or equivalent required.
  • Associate’s degree in Business, Manufacturing, Maintenance, Industrial Technology, or related field required; or an equivalent combination of education and relevant experience. Bachelor’s Degree preferred.
  • Skilled Trades journeymen status or certification from trade school, technical college, or apprenticeship preferred.

Experience:

• • Minimum three (3) years of relevant maintenance experience required.
  • Experience in maintenance and repair operations associated with electrical systems, electronics, fabrication, hydraulics, injection molding, mechanical drives, pneumatics, robotics, stamping, welding, assembly and conveyor systems, and Programmable Logic Controller (PLC) programming and troubleshooting.
  • Minimum two (2) years of leadership or supervisory experience required.
  • Automotive industry experience preferred.
  • Experience in automotive interiors including carpets, filters, powertrain, seating, and/or trim preferred.
  • Working knowledge and experience with the Toyota Production System preferred.
  • Experience in machine shop and injection mold maintenance preferred.