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Maintenance Group Leader

companyToyota Boshoku
locationHopkinsville, KY, USA
PublishedPublished: 6/11/2024
General Maintenance

I. Maintenance Group Leader -- 1st and 2nd Shift

I. G I. General Summary
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.

II. Essential Job Functions:

General

A. Function as a first-line supervisor over team leaders and team members.

1. Plan and coordinate hiring and placement of team members with his/her Assistant Manager. Monitor and track staffing conditions, work hours and overtime, job rotation, and absenteeism.

2. 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.

3. Responsible for managing and appraising team member job performance and recommending corrective action.

4. Develop and maintain positive team member relations centered on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony.

5. Provide direction and motivation to team members emphasizing safety, quality, efficiency, productivity, cost reduction, and morale.

B. 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.

1. Utilize Toyota Production System (TPS) techniques to standardize current/new processes and methods, reduce process variation, identify waste, and methodically eliminate waste.

2. Develop standardized work procedures by designing and/or documenting the best maintenance work sequence for each piece of equipment or tooling.

3. Direct the work of Team Leaders and Team Members by assigning/re-assigning work stationing based on current work situation and production schedules.

4. 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.

5. Perform the essential job functions of team leaders or team members as necessary to maintain efficient, stable, and continuous operations.

C. Direct and control maintenance activities on all production equipment, facilities, and utility systems to provide a reliable production platform.

1. Develop predictive and preventive maintenance programs in conjunction with production management to ensure operability of all plant production equipment and facilities.

2. Monitor the Preventive Maintenance (PM) scheduling for completion and performance and evaluate breakdown situations for PM effectiveness.

3. Direct and coordinate activities of team members engaged in repair, maintenance, and installation of machines, tools, and equipment to ensure continuous production operations.

4. Manage and maintain machine uptime/downtime in accordance with departmental and company goals.

5. Coordinate and support maintenance and operations of facilities and utility systems.

6. Obtain part quotations and submit purchase orders for machine, equipment, and tooling repairs.

7. Support spare parts purchases and operation of parts and tooling crib.

8. Research obsolete equipment spare parts and components, design when applicable, and source suitable replacement components or repairs.

9. Responsible for developing maintenance systems that support achievement of company annual plan targets.

D. Utilize knowledge and skills to maintain the highest level of safety and efficiency for machines, tools, equipment, etc. possible.

1. Monitor the flow of parts, materials, productivity, and quality with respect to machine, equipment, and tooling operation; take corrective action as needed.

2. Partner with the Manufacturing department to initiate investigation and containment activities.

3. 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.

4. Troubleshoot daily safety, machine, equipment, and tooling issues.

5. Be proactive in predicting abnormalities and finding innovative solutions to correct.

6. Evaluate and analyze problems involving machinery and equipment and coordinates repair of tools and machinery. Participate in frequent evaluation of machines, tools, equipment, etc.

E. Lead continuous improvement activity for assigned area.

1. Participate in the setting of Key Performance Indicator (KPI) targets as a method of continuous improvement.

2. Maintain, monitor, and update department and KPI board and graphs, daily, and initiate continuous improvement activities.

3. Initiate, coordinate, and participate in safety, productivity, and cost improvement projects.

4. Lead the implementation of team members' ideas and suggestions and Management directed initiatives.

F. Maintain a safe working environment for all team members.

1. Ensure compliance with safety regulations, PPE requirements, and company safety policies and procedures.

2. Lead, perform, and/or participate in 5S housekeeping, accident investigation, and safety audits and related activities.

3. Maintain knowledge of procedures concerning Hazardous Waste, Spill Response, and Plant Security.

4. Monitor safety and health of team members to ensure their well-being.

G. Train and coach team members to maintain productivity and quality standards, in TS19649, ISO 14001, environmental, safety, quality, job performance, setups, trouble shooting, continuous improvement, and maintenance and repair operations.

1. 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.

2. Maintain training matrix for team leaders and/or team members, assuring training is effective and corrects substandard performance.

3. Responsible for multi-skills training to effectively handle breakdown situations.

4. Maintain, plan, and prepare department instruction manuals.

5. Ensure further development of team members through performance evaluation, development of training plans, feedback, coaching, and cascade training.

H. Collect, record, and analyze information while maintaining documentation regarding the activities in the assigned area as defined by company policy, procedure, or practice.

1. Prepare business reports and spread sheets of required data.

2. 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.

3. Monitor and maintain team member time, attendance, and training records.

I. Communicate frequently with internal contacts on various issues.

1. Through daily communication meetings, keep team members informed on issues relevant to them and encourage two-way communication.

2. 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.

3. Coordinate communications between shifts for assigned area(s).

III. Minimum Qualifications/Requirements:

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.

Personal/Technical Skills:

• Demonstrated knowledge, skills, and abilities to perform the job functions of a leadership role.

• Ability to troubleshoot and track equipment issues to perform root cause analysis and correct issues with equipment suppliers.

• Must have a good working knowledge of industrial technology and technological advances.

• General understanding and working knowledge of skill areas including electrical, electronics, fabrication, hydraulics, injection molding, mechanical drives, pneumatics, robotics, stamping, welding, assembly and conveyor systems, and PLC programming.

• Must be able to work in a multi-skilled environment with maintenance aptitude to learn skilled trades other than area of expertise.

• Ability to read and interpret blue prints, schematics, drawings, specifications, and technical instruction manuals.

• Thorough understanding of company product, trade terminology, maintenance and repair operations, manufacturing processes, and machine/equipment operation.

• General understanding and working knowledge of manufacturing and assembly equipment and tooling including design, automation, robotics, or manufacturing processes (and all secondary related processes) relating to automotive interiors.

• Working knowledge of shop mathematics and the use of a variety of measuring devices and instruments.

• Ability to effectively facilitate problem solving and resolution.

• Ability 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 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.

• Ability to diagnose problems for true root cause and implement effective countermeasures.

• Must be able to work a fixed or rotating shift schedule, including daily or weekend overtime.

• 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.

Language Skills:

• Strong verbal and written communication skills in English.

Computer/Software:

• Previous experience working with integrated computer programs and/or applications. ERP System experience (e.g., Oracle) preferred.

• Solid working knowledge and demonstrated experience with Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Outlook, Internet, etc.).

Training Requirements:

Must be willing to successfully complete and use training for items below:

• Machines, tools, tooling, equipment, and other motorized or maintenance related equipment (e.g., cranes, lift trucks, etc.).

• Cross training for leading other plant support departments.

• RCRA and DOT hazardous waste requirements, and pass certification.

• Computer-based software, applications, and systems (e.g., Oracle, Kronos, Future 3, etc.).

IV. 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: Minimal (Able to travel to Japan for training and benchmark activities-Able to travel to other TBA facilities for training and benchmark activities.)

V. 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, stooping, 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 30-50 pounds (with or without assistance).

Toyota Boshoku America is an equal opportunity employer and considers applications for all positions without regard to race, sex, religion, color, national origin, pregnancy, genetic information or any other characteristic protected by applicable law. If you require a reasonable accommodation to apply for a posted position, please email us at .

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