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Quality Operations Manager

2 months ago

Washington DC USA, United States Toyota Boshoku Full time
Job Summary

We are seeking a highly skilled and experienced Quality Operations Manager to join our team at Toyota Boshoku America. As a key member of our manufacturing operations team, you will be responsible for overseeing the shipping and receiving warehouse operations, directing team leaders and team members, and ensuring the highest level of quality and efficiency in our production processes.

Key Responsibilities
  • Oversee the shipping and receiving warehouse operations, including shipping, receiving, inventory control, and product delivery to manufacturing
  • Direct team leaders and team members in assigned manufacturing areas, ensuring the execution of group responsibilities and accomplishment of company goals and targets
  • Manage group operations as an operational unit, responsible for safety, product quality, customer satisfaction, accuracy, productivity, cost reduction, housekeeping, efficiency, training, teamwork, and morale
  • Monitor and track staffing conditions, work hours, and overtime, as well as job rotation and absenteeism
  • Ensure compliance with all company rules, policies, and practices, and take corrective action when warranted
  • Manage and appraise team member job performance, recommending corrective action as needed
  • 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 areas, accomplishing department hoshin goals and keeping on task with targets and implementation schedules
  • Utilize Toyota Production System (TPS) techniques to standardize current/new processes and methods, reduce process variation, identify waste, and eliminate waste
  • Develop standardized work procedures by designing and/or documenting the best work sequence for each process
  • 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, and ensure quality goals and standards are met
  • 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 adjustments to ensure quality, safety, operational availability, production efficiency, and cost are maintained
  • Evaluate and analyze problems involving machinery and equipment, and coordinate repair of tools and machinery
  • Participate in frequent evaluation of machines, tools, equipment, etc.
  • Participate in the setting of Key Performance Indicator (KPI) targets, including safety, quality, operational availability, production efficiency, scrap, etc.
  • 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
  • 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 workstations 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
  • 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
  • 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
  • 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 areas
  • Prepare layout and internal logistic routing inside of the plant
  • Construct racks and shelves for new parts
  • Manage daily kanban system for assigned area
  • Assign truck runs daily
  • Ensure on-time delivery of parts and materials to lines/production areas
  • Verify daily inventory levels and cycle counts
  • Ensure parts and materials are sorted, rotated, and used in accordance with the inventory handling method (e.g., FIFO)
  • Manage the handling and communication of parts shortages
  • Count finished goods bank and ensure data entry in PC information system
  • Monitor and react to finished goods bank levels
  • Print shippers and send Advance Shipping Notices (ASN)
  • Relay information to other departments to meet shipping deadlines
  • Ensure production and shipment data is uploaded into PC information system as required
  • Ensure data entry in PC information system
  • Maintain constant communication between suppliers (i.e., truck appointments, problems)
  • Contact Production Control staff or customer for broadcast issues
  • Ensure empty returnable containers/packaging are shipped to correct supplier
  • Receive resin loads for silo, calculate proper unloading site, and authorize unloading
  • Coordinate recycling program to ensure all materials are properly disposed of
  • Inspect and audit areas and equipment daily (e.g., recycle area, mix room, balers) to ensure safety and efficiency standards are met
  • Conduct frequent audits of warehouses and assembly lines/production areas to ensure proper material distribution and response to breakdowns or other abnormalities
  • Inspect warehouse layout and inventory min/max signs to maintain a safe level of inventory
  • Check forklift and tugger log books
Requirements
  • Associate's degree in Business, Manufacturing, or related field required, or an equivalent combination of education and experience
  • Bachelor's degree preferred
  • Minimum three (3) years of relevant manufacturing experience required
  • Automotive industry experience preferred with parts production, quality, or production control experience a plus
  • Working knowledge and experience with TPS and Production Efficiency (PEFF) system preferred
  • Working knowledge of kanban system, truck/delivery schedules, hazardous waste disposal, and inventory level management
  • Ability to obtain and maintain certification in Forklift/Material Handling operation and Hazardous Waste handling
  • Must be able to work a fixed or rotating shift schedule, including daily or weekend overtime
  • Thorough understanding of company product, trade terminology, quality management and control systems and techniques, manufacturing processes including material controls, work flow, scheduling, kanban, machine operation, and company policies as standards
  • Ability to be flexible in a constantly changing production environment
  • Must be able to multi-task, handle diversity, and provide leadership through problem resolution
  • Ability to adapt available skills and equipment to respond to unforeseen demands and/or problems
  • Ability to implement plans to control and maintain safety, quality, 5S, cost, and efficiency for assigned areas
  • Strong organization, time management, and planning skills and ability to manage multiple tasks with tight deadlines
  • Ability to teach team leaders and team members in basic fundamental skills and facilitate Job Instruction Training (JIT)
  • Strong verbal and written communication skills in English
  • Previous experience working with integrated computer programs and/or applications (Oracle) preferred
  • Solid working knowledge and demonstrated experience with Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Lotus Notes/Outlook, Internet, etc.)
Work Environment/Conditions

Office: Open Office Environment, moderate noise level

Plant: Various types of manufacturing environments

Standard automotive plant environment with moderate noise level

PPE (Personal Protective Equipment) such as safety glasses, steel toe shoes, Kevlar sleeves, hearing protection, etc. may be required in designated engineering, manufacturing, or industrial areas

Travel: Minimal