Process Coach, Maintenance

Ford Motor Company; Pretoria; On-site; ZAR 500,000 - 650,000; Full time

Job summary

A leading company is seeking a Process Coach responsible for supervising the maintenance team and ensuring production continues safely and efficiently. The ideal candidate will have at least 3 years' experience in the automotive sector and possess a National Diploma in Mechanical/Electrical fields. You'll monitor processes, ensure adherence to safety and quality standards, and drive continuous improvement initiatives across the maintenance department.

Qualifications

• 3 years' experience in the Automotive industry
• 3 years' experience in a Maintenance background
• Proficient in Microsoft Office (Word/PowerPoint/Excel/Outlook)

Responsibilities

• Supervise the Maintenance team and ensure processes run safely and smoothly.
• Analyze breakdown reports and implement corrective measures.
• Implement PM strategy and ensure optimal equipment maintenance.

Skills

Fault-finding ability

Programming skills

6 Sigma problem-solving Methodology

Education

3 years National Diploma in Mechanical / Electrical or N6 with a Trade certificate

Tools

Kawasaki Robotics

Fanuc Robotics

Siemens TIA Portal

Mitsubishi PLCs

Job description

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

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.

Responsibilities

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.