Manager - Poka Yoke Manufacturing

Morgan Street Holdings; Jakarta Pusat; Hybrid; IDR 700,000,000 - 1,300,000,000; Full time

Job summary

tms in Jakarta is seeking a Manager – Poka Yoke Manufacturing to lead the Poka Yoke team, defining how production lines will be designed and set up, ensuring robust realization from development through mass production.

The role collaborates with Quality Assurance, Production Engineering, and Vendors to implement fool-proofing, maintain product safety, and drive process stability across the line. Travel may be required.

Qualifications

• Bachelor-level degree in a relevant engineering discipline required.
• Proven experience in manufacturing engineering for consumer toys or similar high-volume products.
• Strong leadership experience with 3+ years of people management.

Responsibilities

• Lead, mentor, develop, and performance-manage a team of Poka Yoke Manufacturing.
• Proactively interface with Quality Assurance, Production Engineering and Vendors from development stage onwards. Provide input on manufacturing line and fool-proofing manufacturing processes to ensure designs are optimized for manufacturing and meet quality and safety requirements.
• Identify potential defects in planned manufacturing processes and production line layouts; monitor factory to develop alternative solutions and improvements.
• Define requirements for new manufacturing tools, fixtures, jigs, and production equipment, including automation solutions.
• Oversee setup and validation of new production lines; manage pilot runs to ensure process stability and product safety and quality.
• Conduct FMEA and Poka-Yoke principles to continuously refine and optimize processes.
• Establish process control plans and validation activities to ensure consistent quality and safety performance.
• Ensure factories conduct trials, capability studies, and production readiness reviews before mass production.
• Collaborate with Engineering, Quality, and Production to resolve design and manufacturing issues.
• Ensure root cause analysis and CAPA are effective to drive long-term stability.
• Support audits related to manufacturing processes control.

Skills

Analytical thinking

Problem solving

Communication & influence

Reading engineering drawings

Data-driven decision making

Root cause analysis

Education

Degree in Manufacturing Engineering

Industrial Engineering

Mechanical Engineering

Tools

Lean manufacturing

Six Sigma

PFMEA

Control Plan

SPC

SOPs

Job description

Select how often (in days) to receive an alert:

Manager - Poka Yoke Manufacturing

Workplace Type: Hybrid

ABOUT US

tms unites technology, marketing, and sourcing to drive transformational change for the world’s leading brands. With 1,200+ employees across 26 countries, we offer an impressive range of solutions – from inspiration and innovation to category management and delivery.

Operating as a creative agency, a strategic consultancy, a sourcing business, and a technology provider, we engage with over 110 million customers every single day for our clients, including McDonald’s, T-Mobile, O2, Starbucks, and adidas.

Most importantly, we're a place where you can achieve great things, and be recognized as the best.

WHAT MATTERS THE MOST

Breakthrough, business-driving ideas come from extraordinary people with the freedom to be their most authentic selves at work. Authenticity and diversity are critical elements of our business. They can only be realized when we create access and equity for all. We foster a culture of inclusion and belonging and aspire to be ever-evolving.

tms is a place where brilliant people are better together. If you want your ideas to be heard and to contribute to a culture of inclusion and authenticity, bring us your voice! Visit us at tmsw.com .

Job Summary:

The Manager – Poka Yoke Manufacturing plays a pivotal role at the intersection of production line development and production reality. This position is to lead the Poke Yoke Manufacturing team to define how production line will be design and set up, ensuring their robust and effective realization from production line development stage through to mass production.

The Manager – Poka Yoke Manufacturing is responsible for the implementation of Poke Yoke technique in Happy Meal production line design, development and execution, to ensure product quality and safety, and stable and consistent manufacturing processes and control.

The Poka Yoke Manufacturing team proactively collaborates with Production Engineering, Quality Assurance and Vendors to look at manufacturing process and line set up at the early stage, meticulously plans and mistake-proofing manufacturing processes to ensure safe and quality products produced.

Job Relationships

Internal – Global Quality & Safety Team, Product Development Engineers (based in Hong Kong and China), Supply Chain Operations, TMS Agency

External – Manufacturing Vendors, Tool Makers, Factories, Subcontractors, Raw Material Suppliers.

Job Responsibilities

• Lead, mentor, develop, and performance-manage a team of Poka Yoke Manufacturing
• Proactively interface with Quality Assurance, Production Engineering and Vendors from development stage onwards. Provide input on manufacturing line and Fool-proofing manufacturing processes to ensure the product and processes designs are inherently optimized for manufacturing and to meet TMS/client quality and safety requirements.
• Identify potential defects in planned manufacturing processes and production line layouts. Monitor factory to develop alternative solution, mitigation actions, improvement, or equipment introduction to prevent production quality and safety issues.
• Define the requirements for, and support the design and qualification of new manufacturing tools, fixtures, jigs, and production equipment, including automation solutions.
• Oversee the setup and validation of new production lines, manage pilot runs ensuring process stability and product safety and quality.
• Conduct FMEA and Poka-Yoke principles and methodologies to drive factory continuously refine and optimize production processes and setup to ensure the product safety and quality.
• Establish process control plans and conduct validation activities to ensure the production processes and setup with consistent quality and safety performance.
• Ensure factory to conduct appropriate process trials, capability studies, and production readiness reviews before mass production
• Collaborate with factories’ Engineering, Quality, and Production to resolve design and manufacturing issues
• Ensure factory’s root cause analysis (RCA) and corrective and preventive actions (CAPA) is effective to drive long‑term process stability
• Provide support and follow up on company quality and safety initiatives
• Support internal and external audits related to manufacturing processes control

Qualifications/Experience

• Solid experience and technical expertise in plastic toys, premium & children’s products.
• At least 10 years working experience in toys industry with progressive experience in a manufacturing engineering role
• At least 3 years of people management or supervisory experience
• Profound understanding and practical experience with Design for Manufacturing, FMEA, Poka-Yoke with a proven ability to influence product/process design.
• Expertise in manufacturing processes setup and improvement: Lean, Six Sigma, PFMEA, Control Plan, SPC, SOP. In-depth knowledge of various manufacturing processes in toys production
• Demonstrated success managing NPI
• Proven experience working with factories in high volume production.
• Familiar with factory automation technologies
• Good knowledge in a variety of other product areas

Education

• Degree in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or a closely related technical field from an accredited institution.

Job Knowledge/Skills

• Strong analytic thinking with excellent problem-solving ability.
• Good knowledge on plastic product design and mold making processes.
• Good communication and influence skills.
• Good spoken and written English.
• Ability to read technical drawings, interpret engineering specifications, and analyze production data
• Data-driven Decision Making
• Strong Problem-Solving & Root Cause Analysis

Other Requirements

• Reliable and strong character.
• High integrity and business ethics.
• Team Player.
• Proactive, self-motivated and able to work independently
• Able and willing to travel outside Indonesia