Quality Control Group Leader

4 weeks ago

Hopkinsville, Kentucky, United States Toyota Boshoku Full time
Job Summary

We are seeking a highly skilled Quality Control Group Leader to oversee the quality control operations during the designated shift. The ideal candidate will have a strong background in quality control, leadership, and manufacturing operations.

Key Responsibilities
  • Oversee quality control operations during the designated shift
  • Direct Team Leaders and Team Members in assigned manufacturing area
  • Manage group (manufacturing line, cells, or area) as an operational unit
  • Responsible to accomplish company goals and targets in accordance with all company policies, manufacturing standards and methods, and quality standards
  • Monitor and track staffing conditions, work hours and overtime, job rotation, and absenteeism
  • Understand, execute, and ensure consistent compliance with all company rules, policies, and practices
  • Responsible for managing and appraising team member job performance and recommending corrective action
  • Develop and maintain positive team member relations centered on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony
  • Provide direction and motivation to team members emphasizing safety, quality, efficiency, productivity, cost reduction, and morale
  • Lead and maintain the manufacturing and production system of assigned area, accomplishing department hoshin goals, and keeping on task with targets and implementation schedule
  • Measure products by CMM each shift and judge OK / Not OK according to standards
  • Utilize Toyota Production System (TPS) techniques to standardize current/new processes and methods, reduce process variation, identify waste, and methodically eliminate waste
  • Develop standardized work procedures by designing and/or documenting the best work sequence for each process
  • Direct the work of Team Leaders and Team Members by assigning/re-assigning work stationing and analyze production requirements based on current work situation and production schedules
  • Direct floor activities through consistent application of Toyota Boshoku Business Practices (TBBP) to ensure all aspects of manufacturing are effective and correct sub-standard situations
  • Perform the essential job functions of team leaders or team members as necessary to maintain efficient, stable, and continuous operations
  • Utilize knowledge and skills to maintain the highest level of quality and efficiency possible
  • Monitor the flow of parts, materials, productivity, and quality including kanbans and inventory levels; take corrective action as needed
  • Ensure quality goals and standards are met and know how to use the quality feedback loops and systems and escalation procedures
  • Partner with the Quality department to initiate investigation and containment activities
  • Troubleshoot daily quality, safety, and production issues
  • Identify potential and current change points and make the required adjustments needed to ensure quality, safety, operational availability, production efficiency (PEFF), and cost are maintained
  • Be proactive in predicting abnormalities and finding innovative solutions to correct
  • Evaluate and analyze problems involving machinery and equipment and coordinates repair of tools and machinery
  • Participate in frequent evaluation of machines, tools, equipment, etc.
  • Lead continuous improvement activity for assigned area
  • Participate in the setting of Key Performance Indicator (KPI) targets including safety, quality, operational availability, PEFF, scrap, etc. as a method of continuous improvement
  • Maintain, monitor, and update department and KPI board and graphs, daily, and initiate continuous improvement activities
  • Initiate, coordinate, and participate in safety, quality, productivity, and cost improvement projects
  • Lead the implementation of team members' ideas and suggestions and management directed initiatives
  • Maintain a safe working environment for all team members
  • Ensure compliance with safety regulations, Personal Protective Equipment (PPE) requirements, and company safety policies and procedures
  • Lead, perform, and/or participate in ergonomic exercises, 5S housekeeping, accident investigation, and safety audits and related activities
  • Lead ergonomic assessments of team member work stations and implement countermeasures and job rotation to improve long-term safe working conditions and team member well-being
  • Maintain knowledge of procedures concerning Hazardous Waste, Spill Response, and Plant Security
  • Monitor safety and health of team members to ensure their well-being
  • Train and coach team members to maintain productivity and quality standards, in TS19649, ISO 14001, environmental, safety, quality, job performance, setups, trouble shooting, and continuous improvement
  • Orientate and oversee all training of team members and assign experienced and/or certified trainers to perform new team member training and cross training as needed
  • Maintain training matrix for team leaders and/or team members, assuring training is effective and corrects sub-standard performance
  • Maintain, plan, and prepare department instruction manuals
  • Ensure further development of team members through performance evaluation, development of training plans, feedback, coaching, and cascade training
  • Collect, record, and analyze information while maintaining documentation regarding the activities in the assigned area as defined by company policy, procedure, or practice
  • Prepare business reports and spreadsheets of required data
  • Maintain specified records, files and logs of department/shift activities such as production, production problems, parts shortages, scrap, quality, maintenance, etc. (manual and computer) as required
  • Perform other various administrative duties
  • Monitor and maintain team member time, attendance, and training records
  • Communicate frequently with internal contacts on various issues
  • Through daily communication meetings, keep team members informed on issues relevant to them and encourage two-way communication
  • Maintain daily and/or frequent communication with upstream and downstream groups/areas and support departments to ensure efficient and stable operations in a team-based environment
  • Coordinate communications between shifts for assigned area(s)
Functional Responsibilities
  • Support the Quality Manager and overall plant quality system
  • Establish and maintain quality standards that meet or exceed customer requirements
  • Communicate customer or supplier quality issues to manufacturing, production control, and quality control departments
  • Initiate effective containment and investigation activities to prevent further quality problem/defect outflow in-house and to customer
  • Effectively communicate with customers and/or suppliers to resolve quality problems
  • Investigate and countermeasure internal quality defects to improve plant processes
  • Ensure proper quality processes and procedures are followed and maintained plant wide
  • Work with all departments and all levels of management to promote quality

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