Manufacturing Assistant Manager

General Summary:  Supervise Manufacturing department group leaders, team leaders, and team members for assigned area(s)/shift (e.g., assembly, filter, injection molding, powertrain, stamping, urethane, welding, etc.) to ensure safety, quality, positive work environment, customer requirements, and manufacturing needs are met through the Toyota Production System (TPS) philosophy.  Provide leadership and motivation to direct reports in manufacturing system that emphasizes safety, quality, customer satisfaction, accuracy, productivity, cost reduction, housekeeping, efficiency, training, teamwork, and morale.  

II.    Essential Job Functions:
A.    Coordinate and supervise all manufacturing activities and related functions for assigned area(s)/shift to meet customer requirements.
1.    Maintains knowledge and control over assigned areas/shift to ensure proper work schedules and material flow; proper use of manpower skills, equipment and facilities; proper application of methods and related matters.
2.    Ensure manufacturing operations are running effectively in the areas of safety, quality, efficiency/productivity, cost, and team member morale.
3.    Provide direction and motivation to group leaders focusing on safety, quality, efficiency, cost, and morale.
4.    Conduct daily manufacturing production area audits to ensure procedures for safety, quality, equipment, and training are being followed and all aspects of manufacturing are effective including correcting sub-standards.
5.    Lead development of Group Leaders in the consistent application of the TB Way and Toyota Boshoku Business Practices (TBBP).
6.    Implement short and long term corrective actions for manufacturing problems.
7.    Ensure all departmental procedures are complaint with quality and environmental management systems and programs.
8.    Monitor daily build sheets and analyze efficiency rates and downtime to ensure customer requirements are being met.
B.    Lead Manufacturing supervision for assigned areas/shift in utilizing TPS techniques.
1.    Learn, embrace, implement, and teach TPS techniques to Manufacturing team members.
2.    Coordinate and maintain standardization of processes/methods and one piece flow in Just in Time (JIT) production system.
3.    Lead identification of manufacturing problems and eliminate waste.
4.    Develop, lead, monitor, and participate in a Manufacturing continuous improvement system.
5.    Kaizen and develop processes that lower operating costs and increase efficiency.
6.    Implement, monitor, and maintain a clean, organized department through 5S activity.
C.    Support development and management of annual plan, budget, Key Performance Indicators (KPI), operating efficiency, and cost control.
1.    Ensure Manufacturing hoshin goals are met and kept on track.
2.    Assists Manufacturing Manager in developing, planning, and maintaining the budget including making adjustments to achieve targets.
3.    Assist in the review and planning of headcount monthly for labor cost control and production efficiency (PEFF).
4.    Review and track Manufacturing KPIs including leading problem solving for negative trends or goals not met.
5.    Collect, record, and analyze data on production, quality, scrap, rework, change over time, machine downtime, and direct and indirect labor.
6.    Assist with generation and report out of daily/weekly/monthly reports with targets.
7.    Participate in management discussions and planning sessions to help formulate cost reduction, product improvement, and problem solving activities, and support presentation of operational performance daily/weekly.
D.    Develop and maintain positive team member relations centered on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony.
E.    Provide direction and motivation to team members emphasizing quality, efficiency, productivity, cost reduction, safety and health, and morale.
F.    Ensure further development of group leaders, team leaders, and 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.

            
III.    Minimum Qualifications/Requirements:

Education: 
•    Bachelor’s Degree in Engineering, Business, or related field required, or an equivalent combination of education and relevant experience.

Experience:
•    Greater than 6 years of relevant work experience in a manufacturing environment required, preferably automotive.
•    Greater than 2 years of leadership experience as supervisor in a manufacturing environment required.

Personal/Technical Skills:
•    Thorough understanding of company product, trade terminology, quality management and control systems and techniques, manufacturing processes including material controls, work flow, scheduling, kanban, and equipment and machine operation.  
•    Working knowledge of automotive industry equipment and production systems.
•    General understanding and practical work experience with manufacturing systems and processes.
•    Practical experience applying Toyota Production System (TPS) principles in an automotive environment.
•    Versed in statistical data entry and utilization of trend analysis.
•    Advanced math skills.
•    Strong leadership skills and ability.
•    Excellent problem solving and people skills.
•    Ability to work in a fast-paced, multicultural environment.
•    Ability to effectively facilitate problem solving and resolution.
•    Ability work with a dynamic team and demanding customer(s).
•    Excellent collaboration and interpersonal communication skills.
•    Ability to read instruction manuals, blue prints, 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.
•    Ability to communicate and work well with others in a team environment. 
•    Ability to speak to groups of people and make presentations to executive groups.
•    Ability to multi-task, handle diversity, and provide leadership through problem resolution.
•    Must be able to work a fixed or rotating shift schedule, including daily or weekend overtime.
•    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 group leaders, team leaders, and team members in basic fundamental skills and facilitate Job Instruction Training (JIT).

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.).

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:  Must be willing to travel up to 10% of the time.

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 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.

Disclaimer: This job description is intended to identify the general nature and level of work performed by team members within this classification, as well as certain essential job functions. It is not intended, and should not be interpreted, as a comprehensive inventory of all duties, responsibilities, and qualifications required of team members assigned to this job. To qualify for this job, however, a team member must be able to perform its essential functions with or without reasonable accommodation. Under no circumstances may this job description be construed as altering the at-will nature of the employment relationship between TBA and any team member.