Production Control Group Leader - 2nd Shift

Overview:

Manages group (receiving, stores, material handling, etc.) as an operational unit and responsible to accomplish company goals and targets in accordance with all company policies, manufacturing standards and methods, and process standards for safety, product quality, customer satisfaction, accuracy, productivity, cost reduction, housekeeping, efficiency, training, teamwork, and morale.

Responsibilities:

1. Function as a first-line supervisor over team leaders and team members.
2. Plan and coordinate hiring and placement of team members with his/her Manager or Assistant Manager. Monitor and track staffing conditions, work hours and overtime, job rotation, and absenteeism.
3. Understand, execute, and ensure consistent compliance with all company rules, policies, and practices, and takes appropriate corrective action when warranted, in accordance with the terms of the Team Member Handbook.
4. Responsible for managing and appraising team members’ job performance and recommending corrective action.
5. Develop and maintain positive team member relations centered on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony.
6. Provide direction and motivation to team members emphasizing safety, quality, efficiency, productivity, cost reduction, and morale.
7. Responsible for leading and maintaining the production control activities of assigned areas, accomplishing department hoshin goals, and keeping on task with targets and implementation schedule.
8. Utilize Toyota Production System (TPS) techniques to standardize current/new processes and methods, reduce process variation, identify waste, and methodically eliminate waste.
9. Develop standardized work procedures by designing and/or documenting the best work sequence for each process.
10. Direct the work of Team Leaders and Team Members by assigning/re-assigning work processes and analyzing production control requirements based on current work conditions and production schedules.
11. Direct floor activities through consistent application of Toyota Boshoku Business Practices (TBBP) to ensure all aspects of production control are effective and correct all sub-standard situations.
12. Perform the essential job functions of team leaders or team members as necessary to maintain efficient, stable, and continuous operations
13. Utilize knowledge and skills to maintain the highest level of process quality and efficiency possible.
14. Monitor the flow of parts, materials including kanban and inventory levels; take corrective action as needed.
15. Ensure process goals and standards are met and know how to use the quality feedback loops and systems and escalation procedures. Confirm that team members use all process standards, work instruction and work point sheets correctly.
16. Partner with the Quality department to initiate investigation and containment activities (as needed).
17. Troubleshoot daily safety, production control and cost improvement issues and projects.
18. Identify potential and current change points and make the required adjustments need to ensure quality, safety, cost and process effectiveness are maintained.
19. Be proactive in predicting abnormalities and find innovative solutions to correct as soon as they are detected.
20. Evaluate and analyze problems involving machinery and equipment (forklifts, tuggers, boom lift, scissor lift, scanners, etc.) and coordinates repair of tools and machinery. Participate in frequent evaluation of machines, tools, equipment, etc.
21. Lead continuous improvement activity for assigned areas.
22. Participate in the setting of Key Performance Indicator (KPI) targets including safety, quality, production control processes, etc. as a method of continuous improvement.
23. Maintain, monitor, and update department and KPI board and graphs, daily, and initiate continuous improvement activities.
24. Initiate, coordinate, and participate in safety, productivity, and cost improvement projects.
25. Lead the implementation of team members’ ideas and suggestions and management directed initiatives.
26. Maintain a safe working environment for all team members.
27. Ensure compliance with safety regulations, Personal Protective Equipment (PPE) requirements, and company safety policies and procedures.
28. Lead, perform, and/or participate in ergonomic exercises, 5S housekeeping, accident investigation, and safety audits and related activities.
29. Lead ergonomic assessments of team member workstations and implement countermeasures and job rotation to improve long-term safe working conditions and team member well-being.
30. Maintain knowledge of procedures concerning Hazardous Waste, Spill Response, and Plant Security.
31. Monitor the safety and health of team members to ensure their well-being.
32. Train and coach team members to maintain productivity and quality standards, in ISO9001/TS19649, ISO 14001, environmental, safety, quality, job performance, setups, trouble shooting, and continuous improvement.
33. Orientate and oversee all training of team members and assign experienced and/or certified trainers to perform new team member training and cross training as needed.
34. Maintain training matrix for team leaders and/or team members, assuring training is effective and corrects sub-standard performance.
35. Maintain, plan, and prepare department instruction manuals, work instructions and work point sheets.
36. Ensure further development of team members through performance evaluation, development of training plans, feedback, coaching, and cascade training.
37. Collect, record, and analyze information while maintaining documentation regarding the activities in the assigned area as defined by company policy, procedure, or practice.
38. Prepare business reports and spread sheets of required data.
39. Maintain specified records, files and logs of department/shift activities such as part receiving, receiving issues, short shipments (receiving), parts shortages (warehouse), scrap, maintenance, etc. (via manual posting or computer) as required. Perform various other administrative duties.
40. Monitor and maintain team member time, attendance, and training records.
41. Communicate frequently with internal contacts on various issues.
42. Through daily communication meetings, keep team members informed on issues relevant to them and encourage two-way communication.
43. 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.
44. Coordinate communication between shifts for assigned areas.

Qualifications:

Education:

• Associate’s degree in Business, Production Control, Supply Chain Management or related field required, or an equivalent combination of education and experience. Bachelor’s degree preferred.

Experience:

• Minimum of three (3) years of relevant manufacturing experience required.
• Minimum two (2) years of previous leadership or supervisory experience required.
• Automotive industry experience preferred with parts management and production control, production control floor management, production control experience a plus.
• Experience in automotive interiors including seat assembly, seat trim and seat frames and frame welding preferred.
• Working knowledge and experience with Toyota Production System (TPS) and other Toyota management-based philosophies preferred.

Personal/Technical Skills:

• Demonstrated knowledge, skills, and abilities to perform the job functions of a leadership role.
• Must be able to work a fixed shift schedule (1^st or 2^nd shift), including daily or weekend overtime.
• Thorough understanding of company products, trade terminology, quality management and control systems and techniques, manufacturing processes including material controls, workflow, scheduling, kanban, and company policies as standards.
• Good mechanical aptitude.
• Ability to operate forklifts, tuggers, boom lift and scissor lift.
• Experience with Material Requirements Planning (MRP) platforms such as Oracle, SAP, PLEX, etc.
• Experience with the use of hand scanners for use with parts management (receiving, materials transfers, inventories, etc.)
• Experience with time and attendance systems (Kronos user a plus)
• Basic math and analytical skills.
• Ability to effectively facilitate problem solving and resolution.
• Ability to work with a dynamic team and demanding customer(s).
• Ability to work in a fast-paced, multicultural work environment.
• Ability to work with multiple departments and prioritize activities.
• Ability to read instruction manuals, blueprints, and specifications.
• Ability to plan, supervise, and perform functions of assigned areas.
• Ability to maintain on call flexibility to control abnormal conditions.
• Ability to be flexible in a constantly changing production environment.
• Active listener with effective leadership, communication, and interpersonal skills.
• Must be able to multi-task, handle diversity, and provide leadership through problem resolution.
• Ability to communicate and work well with all levels of the organization in a team environment.
• Ability to adapt available skills and equipment to respond to unforeseen demands and/or problems.
• Ability to implement plans to control and maintain safety, quality, 5S, cost, and efficiency for assigned areas.
• Strong organization, time management, and planning skills and ability to manage multiple tasks with tight deadlines.
• Ability to teach team leaders and team members fundamental skills and facilitate Job Instruction Training (JIT).

May be occasionally required to reach, grasp, and manipulate parts, materials, or equipment. May be occasionally required to lift up to 30-35 pounds (with or without assistance).

EOE