Toolroom Manager - Pinetown

Headhunters; Pinetown; On-site; ZAR 900,000 - 1,700,000; Full time

Job summary

Headhunters in KwaZulu-Natal seeks a senior Toolroom and CNC operations leader to oversee the toolroom, design reviews and tooling from design through production handover. Lead a skilled team to ensure quality parts, on-time delivery and efficient tool usage.

The candidate should have 10+ years in automotive engineering/design, 5+ years running engineering projects, and extensive tooling and welding process experience. Strong knowledge of FMEA, control plans and drawings is essential.

Qualifications

• Trade Tested Tool Jig and Die Maker.
• Diploma in Mechanical Engineering, Production Management or Project Management.
• 10 yrs experience in Automotive industry in Engineering and Design.
• 5 yrs experience in running Engineering Projects in Automotive industry.
• Extensive experience in tool Jig and Die Making with progression press tooling.
• Exposure to Co2 welding, resistance welding and spot welding.
• Computer literacy – MS Office.
• Knowledge of tooling manufacture, processes and materials.
• Knowledge of engineering principles around strength of materials.
• Ability to read and interpret engineering drawings and specifications.
• basic financial understanding
• Understand applicable automotive quality standards
• Good spatial skills
• Knowledge of FMEA, Control Plans, work instructions and setup instructions

Responsibilities

• Manage day-to-day operation and performance of Toolroom and CNC machining.
• Lead design reviews for new stamping tools, fixtures and jigs to ensure manufacturability and quality.
• Manage tooling from design through machining, assembly, trial and handover to Production.
• Manage CNC machines, programmers, tool designers and toolmaking staff.
• Coordinate breakdown repairs and root-cause analysis.
• Oversee refurbishment, repairs and engineering changes to tooling.
• Collaborate with cross-functional teams to address quality issues and scrap.
• Interface with external toolmakers and suppliers for tooling or machining work.
• Maintain tooling documentation, drawings, programmes and maintenance records.
• Identify opportunities to improve tool life, reliability and productivity.
• Develop standard practices for tooling design, maintenance and problem solving.
• Lead and develop Toolroom, CNC, programming and design personnel.
• Ensure compliance with IATF 16949 and other quality standards.
• Develop tool and equipment maintenance plans and budgets.
• Analyze breakdowns and ensure tools meet design standards and quality.
• Calculate tonnage, blank size and machinery requirements for parts.
• Determine tooling specifications and cost-effective manufacturing approaches.
• Define deliverables with customers and track progress against KPIs.
• Prepare capex requests and manage budgets.
• Ensure proper job descriptions, KPIs and activity schedules for the team.
• Monitor safety, risk controls and compliance with company policies.

Skills

Automotive engineering

Project management

MS Office

Tooling manufacture

Materials science

FMEA

Control plans

Work instructions

Setup instructions

Education

Diploma in Mechanical Engineering

Diploma in Production Management

Diploma in Project Management

Tools

Progression press tooling

Co2 welding

Resistance welding

Spot welding

Job description

Requirements:

• Trade Tested Tool Jig and Die Maker
• Diploma in Mechanical Engineering/Production Management/Project Management
• 10 yrs experience in the Automotive industry in the Engineering and Design field
• 5 yrs experience in running Engineering Projects in the Automotive industry
• Extensive experience in tool Jig and Die Making - must have worked extensively with progression press tooling
• Extensive exposure to Co2 welding, resistance welding and spot welding
• Computer literacy – MS Office
• A good knowledge of tooling manufacture, processes and materials
• A good knowledge of engineering principle around strength of materials
• Read, understand and interpret engineering drawings and specification
• Basic financial understanding
• Understand applicable automotive quality standards
• Good spatial skills
• Good understanding of tools such as FMEA, Control Plans, work instructions and set up instructions

Responsibilities:

• Manage the day-to-day operation and performance of the Toolroom and CNC machining function.
• Conduct and/or lead design reviews for all new stamping tools, checking fixtures, welding jigs and tooling manufactured internally, ensuring designs are fit for purpose, manufacturable, maintainable and capable of producing quality parts.
• Manage internally manufactured tooling from design through machining, toolmaking, assembly, trial and final handover to Production.
• Manage the CNC machines, CNC programmers, tool designers and toolmaking personnel, ensuring resources and capacity are effectively planned and utilised.
• Manage tool, jig and fixture breakdowns, ensuring timely response, effective repair and identification of root causes for recurring failures.
• Manage minor and major tooling, jig and fixture refurbishments, including repairs, replacement of worn components, modifications and engineering changes.
• Form part of the Cross-Functional Team (CFT) in addressing quality problems, process issues and scrap generated by stamping tools, welding jigs, checking fixtures or machining processes.
• Manage technical interaction with external toolmakers and machining suppliers where tooling or machining is outsourced, including design reviews, progress, trials, modifications and acceptance.
• Ensure tooling, fixture, jig and CNC documentation, drawings, programmes, maintenance records and modification histories are properly controlled.
• Identify opportunities to improve tool life, fixture reliability, machining efficiency, tooling cost and production performance.
• Develop and maintain standard practices for tooling design, maintenance, refurbishment, machining and problem solving.
• Lead, develop and manage Toolroom, CNC, programming and design personnel, ensuring appropriate skills, discipline, productivity and accountability.
• Ensure all activities are performed in accordance with company procedures, engineering requirements, customer requirements, quality standards and applicable IATF 16949 requirements.
• Develop and implement a tool maintenance plan and an equipment Maintenance plan.
• Ensure that the tool maintenance plan accommodates breakdown requirements.
• Analyse reasons for breakdowns and ensure that repaired tools meet design standards and build in mistake-proofing.
• Calculate the tonnage required.
• Calculate the blank size.
• Advise on the machinery required to produce the part, welding jigs, etc.
• Determine special requirements for each set of tooling, to ensure quality standards are met during production.
• Determine type and grade of steel to be used.
• Determine the most cost-effective way to manufacture the part.
• Agree deliverables with the customer.
• Develop a project plan and scope.
• Assign responsibilities.
• Track progress and report back.
• Track actual expenditure vs budget.
• Collate information and submit a capex request where new equipment is required.
• Prove capability.
• MPT to validate quote rates.
• Establish machine capability.
• Create a BOM.
• Timely submission of capex requirements and budgets within the time frame stipulated by Finance.
• Meet the Company and Departmental KPIs within the approved budget.
• Monitor adherence to budget.
• Establish and maintain an effective and cost-effective structure.
• Ensure that all roles and functions are clearly spelt out with regard to Job Descriptions, KPIs, Roles & Responsibilities and Activity Schedules.
• Ensure that all employees have the resources and skills to meet their KPIs.
• Ensure that the appropriate work processes are in place and understood.
• All subordinates understand their authority levels.
• Ensure direct subordinates are performance managed in relation to company and Departmental KPIs.
• Monitor the systems in place to ensure compliance with legislation and company standards.
• Ensure that a regular risk analysis is performed and appropriate plans are in place to mitigate identified risks.
• Coach and train subordinates to ensure that they have all the required competence to meet the company and Departmental Goals and KPIs.
• Ensure that training plans address performance shortfalls.
• Continuously seek opportunities to improve processes and productivity.
• Ensure that successful ideas are implemented.
• Ensure reduction of waste from processes.
• Ensure effective steps are taken to constantly meet Company and Departmental KPIs.
• Ensure direct subordinates are contributing to the Continuous Improvement mindset in their departments.
• Look for opportunities for saving in relation to Company and Departmental KPIs.
• Ensure direct subordinates are meeting their KPIs.
• Daily Operations Meeting.
• Weekly Obeya Meeting.
• Monthly Plant Exco Meeting.
• Ensure on-time and accurate reporting from direct subordinates.
• Ensure that audit findings are resolved timeously.
• Ensure compliance with all Company standards and procedures.
• Ensure all administration and documentation are presented neatly and professionally.
• Ensure that the quality of tools leaving the toolroom is to the defined quality standard of the customer.
• Adhere to all laid-down Company safety policies & the OHS Act.
• Report all unsafe equipment.
• Wear all PPE at all times.
• Ensure an understanding of the departmental budget, as may be applicable, and ensure a practice of cost control.
• Ensure accurate and timely reporting as may apply to the respective KPAs for the position.

Please note that if you do not receive a response within 2 weeks, your application has been unsuccessful.