Operational Development Sr. Specialist

FIC America; Carol Stream (IL); On-site; USD 95,000 - 115,000; Full time

Benefits offered by this job

Medical plans

FSA benefits

401(k) matching

Life Insurance

Long-term Disability

Paid time off

Job summary

FIC America Corp. in the Chicago northwest suburbs is seeking an Operational Development Sr. Specialist to lead Toyota Production System (TPS) practices across production areas.

You will oversee TPS audits, standard work verification, time studies, Kaizen events, training support, and continuous improvement initiatives to improve safety, quality, productivity, and cost reduction. This role requires coaching production supervisors, coordinating cross-functional teams, maintaining documentation,

Qualifications

• Bachelor's degree required.
• Experience in automotive industry required.
• Experience with TPS practices required.
• Prior project coordination in manufacturing environment required.

Responsibilities

• Lead OD/TPS activities across assigned areas to support safety, quality, productivity, cost, delivery, and continuous improvement.
• Plan, assign, and follow up on daily TPS audits to identify waste, safety concerns, and improvement opportunities.
• Lead time studies; verify standard work, cycle times, manpower, line balance, and production targets.
• Review TPS audit results and report findings, trends, and countermeasure status to management.
• Lead Kaizen activities focused on reducing muda and improving material and information flow.
• Coach supervisors on TPS principles, 5S, and waste reduction; ensure proper documentation and training materials are followed.
• Coordinate cross-functional improvement activities to ensure timely completion and sustainability of countermeasures.
• Develop improvement plans and process changes to support safety, quality, productivity, and cost reduction.

Skills

TPS knowledge

Audit leadership

Kaizen

5S

Visual management

Documentation

Education

Bachelor's degree

Tools

ERP systems

Job description

Description

FIC America Corp. is a global Tier 1 automotive components manufacturer centrally located in the Northwest Suburbs of Chicago. We are actively seeking an Operational Development Sr. Specialist. Will be responsible for leading Toyota Production System (TPS) practices and organizational development activities across assigned production areas. This position oversees TPS audits, standard work verification, time studies, Kaizen activities, training support, and continuous improvement initiatives to improve safety, quality, productivity, cost, delivery, and team member engagement. The role provides direction, follow-up, and cross-functional coordination with production, quality, engineering, HR, and management teams to ensure improvement activities are implemented, sustained, and aligned with company objectives.

Essential Duties and Responsibilities

• Lead OD/TPS activities across assigned areas to support company goals for safety, quality, productivity, cost, delivery, and continuous improvement.
• Plan, assign, and follow up on daily TPS audits of both production facilities, and other assigned production areas to identify waste, abnormal conditions, safety concerns, and improvement opportunities.
• Lead time studies and verify standard work, cycle times, manpower requirements, line balance, and production targets for new and existing processes.
• Review TPS audit results, maintain accurate improvement data, and report findings, trends, and countermeasure status to management and responsible departments.
• Lead and support Kaizen activities focused on reducing muda, improving material and information flow, strengthening standardized work, and increasing operational efficiency.
• Provide guidance to production supervisors and team members on TPS principles, problem-solving methods, 5S, visual management, standard work, and waste reduction.
• Verify that shop-floor documents, including standard work, PQC documents, work instructions, and training materials, are clear, current, effective, and properly followed.
• Monitor adherence to TPS standards and escal…
• Coordinate cross-functional improvement activities with production, quality, engineering, HR, maintenance, and management teams to ensure timely completion and sustainability of countermeasures.
• Develop and recommend improvement plans, training needs, and process changes to support safety, quality, productivity, cost reduction, employee development, and overall process efficiency.

Requirements

• Strong understanding of Toyota Production System (TPS) principles, standardized work, Kaizen, 5S, visual management, problem solving, and waste reduction.
• Ability to lead audits, analyze process data, identify abnormalities, and drive corrective actions through follow-up and accountability.
• Ability to lead meetings, assign follow-up actions, manage competing priorities, and communicate expectations clearly across departments and position levels.
• Strong communication skills with the ability to coach team members, support supervisors, provide professional feedback, and present findings to management.
• Ability to coordinate cross-functional activities and influence others to complete improvement actions on time.
• Ability to use data, direct observation, standard work requirements, and TPS audit results to make recommendations and support fact-based decision-making.
• Strong attention to detail and ability to maintain accurate documentation, reports, audit records, improvement tracking, and countermeasure status.
• Proficiency with computer applications used for reporting, data tracking, presentations, and TPS-related documentation.
• Good organizational, problem-solving, leadership, coaching, and decision-making skills.

Work Environment and Expectations

Spend significant time on the production floor observing processes, coaching team members, leading improvement activities, and verifying follow-up actions. Responsible for maintaining strong communication with production, quality, engineering, HR, maintenance, and management teams to ensure TPS activities are completed effectively, sustained over time, and aligned with company expectations.

Other Job Functions

• Comply with FIC’s Safety policies and procedures
• Comply with TS 16949 and ISO 14001 procedures and standards
• Perform 5-S activities

Minimum Requirements

• Experience using Microsoft Word, Excel, PowerPoint, and Outlook
• Multilingual in English, Japanese, and or Spanish is highly desired
• Bachelor's Degree required
• Experience working in an automotive industry is required
• Experience with TPS practices is required
• Prior experience in TPS, continuous improvement, industrial engineering, quality, manufacturing operations, or related process improvement activities are required
• Prior project coordination experience in a manufacturing or production environment required
• ERP experience is preferred
• Valid license is required to drive between production facilities

Pay Range

95,000-115,000/year based on qualifications and experience

Benefits Offered

• Medical plans offered through Blue Cross and Blue Shield, Delta Dental, and VSP Vision
• Flexible Spending Accounts (FSA) Healthcare FSA, Dependent Care FSA, and Transit FSA
• 401(k) – Company will match 50% of the first 6% you contribute to your 401(k)
• Basic Life Insurance and Short-Term Disability paid by employer
• Optional Supplemental Life Insurance and Long-Term Disability (Employee Paid)
• Vacation, Holiday, and Personal Days Paid

About FIC America Corp.

Established in 1994 by Futaba Industrial Co., Ltd., we have been in Carol Stream, IL from the beginning and added an additional facility in Bloomingdale, IL. A Japanese owned manufacturer of stamped and welded products, supplying the automotive industry with performance auto parts, related to emissions, fuel, and exhaust.

FIC America Corp. is an equal opportunity employer. FIC America Corp. does not discriminate based on race, color, sex, sexual orientation, creed, religion, age, national origin, handicap or disability, marital status, veteran status, citizenship status or any other attribute or characteristic protected by law.

We are unable to provide employment-based visa sponsorship now or in the future.