Process Coach, Maintenance

ROLE SUMMARY

The Process Coach is responsible for:

• Supporting Production with well-maintained facilities adhering to World Class Standards.
• Driving SQCDPME by understanding and consistently applying MOS standards and strategies.
• Validate and bridge operational needs to ensure the Production line is running safely and smoothly.
• Supervise, Coach, and be responsible for the Maintenance team.
• Analyze breakdown reports and implement corrective measures.
• Adhere to all safety rules and regulations.
  

POSITION DETAILS

Safety

• Continuously monitor the processes within Maintenance department with a view towards proactively solving potential problems that could have negative impact on the safety well-being of the team.
• Attend to the concerns raised by any department timeously and with urgency.
• Track and monitor all safety concerns including, CCAR’s, PTA’S, near-misses, etc.

Quality

• Ensure all quality standards are adhered to.
• Monitor the quality performance of the Maintenance department on an hourly basis by reviewing the defect status with a view towards conducting deep-dive investigations and implementing ICA’s / PCA.
• Review GTR reports and QLS reports to monitor Quality and partake in Quality meetings to give feedback on Equipment Quality concerns.
• Utilize all the available tools and documentation in order to resolve problems and eliminate defects, e.g., 8D’s, 6 Panel, and PJO’s.

Delivery

• Coordinate the resources and activities required to ensure the MOS strategy is implemented.

Cost

• Monitor, control, and improve Maintenance Cost Per Unit (MCPU) based on the MOS strategy.
• Manage based on MOS strategy and support material control (spare part inventory), repair and rebuild programs, Reliability and Maintainability reviews.
• Drive cost improvement initiatives in order to improve the overall cost efficiency and effectiveness of the Maintenance department by finding ways to reduce the usage of consumables and materials.

People

• Clear communication to the team.
• Administration of supervisory responsibilities and documents
• Leading, coaching, training, and development of the team.
• Conduct PJO’s to verify that the line is running safely and consistently, PM/CM/EM are done with integrity and quality, and Facilities are maintained to the standard by the team.
• Manage absenteeism levels, employee versatility & manning assignments in the area of responsibility.
• Develop the weekend planning work and participate in weekend planning meetings with VOME/Launch.
• Support, Coach and drive Team’s Continuous Improvement mindset through Kaizens, 6 Panels, Proactive actions.
• Hold team Accountable.

Maintenance

• MOS strategy to maximize equipment effectiveness through a detailed, standardized, prioritized preventive and predictive maintenance plan designed to improve productivity.
• Use Maximo to analyze data and evaluate the effectiveness of the preventive maintenance plan.
• Regularly monitor and assess the condition of back-up equipment to ensure readiness for use when needed.
• Know and understand the Maintenance Operating Systems and its objectives.
• Ensure robust PM’s with Visual Job Plans
• Continuously do PJO’s and improve facility uptime.

Environment

• Ensure department complies with government, industry and corporate standards.

QUALIFICATIONS and EXPERIENCE

• 3 years National Diploma in Mechanical / Electrical or N6 with a Trade certificate.
• Proficient in Kawasaki, Fanuc Robotics.
• Electrical and mechanical skills.
• Programming skills.
• Microsoft Office knowledge (Word/PowerPoint/Excel/Outlook).
• Fault-finding ability.
• 6 Sigma problem-solving Methodology.
• Proper communication and escalation
• Knowledge of MOS Implementation.
• Knowledge of constraint management principles.
• Proficient in Siemens TIA Portal, Mitsubishi PLCs
• SEW, Simotion Controls and drives
• Basic knowledge in Vision systems and scanners e.g. Cognex, Sick
• 3 years’ Experience in the Automotive industry
• 3 years’ Experience in a Maintenance background
• Must have displayed proven capability of leading a team in current or previous roles.

PERFORMANCE MEASURES/ SUCCESS CRITERIA

• Ensure PM strategy is implemented and followed, PM’s are done with integrity
• Install / repair equipment within the timing plan.
• Analyze the work performed by team to ensure good performance.
• Ensure efficient utilization of the team.
• Produce well-defined reports when requested for future planning or to substantiate the progress of a task or project.
• Ensure the adherence to the Company Code of Conduct and Safety rules.
• Train subordinates to maximize productivity.
• Ensure the availability of the required spares for emergency and planned repairs
• +95% Equipment Availability
• Reduce breakdown Mean Time To Repair (MTTR) to < 9min
• Increase Equipment MTBF to > 450min
• PM completion ratio of > 97%
• No Open Work Orders > Three months
• Unplanned absentee management of < 3%

KNOWLEDGE, SKILLS and ABILITIES

• Foster functional & Technical Excellence
  • Know and have a passion for our business and our customers.
  • Demonstrate and build functional and technical excellence.
  • Ensure process discipline.
  • Have a continuous improvement philosophy and practice.
• Own Working Together
  • Believe in skilled and motivated people working together.
  • Include everyone, respect, listen to, help and appreciate others.
  • Build strong relationships/be a team player/develop ourselves & others.
  • Communicate clearly, concisely and candidly.
• Role Model Ford Values
  • Show initiative, courage, integrity, and good corporate citizenship.
  • Improve quality, safety, and sustainability.
  • Have a can do, find a way attitude and emotional resilience.
  • Enjoy the journey & each other. Have fun – never at others’ expense.
• Deliver Results years
  • Deal positively with our business realities, develop compelling & comprehensive plans while keeping an eye on the enterprise view.
  • Set high expectations and inspire others.
  • Make sound decisions using facts and data.
  • Hold ourselves and others responsible and accountable for delivering results and satisfying our customers.
  • Strong problem-solving and conflict management skills.