Process Coach.

The Process Coach (PCE) in Final Assembly leads daily shift operations and the hourly line team at HSAP. This role ensures a safe shift startup and shutdown, enforces standardized work at all levels, and coordinates with cross-functional support teams (Maintenance, Quality, Tooling, Dimensional, Incoming Quality, VRT, Body, Paint, and Finance/Costs) to resolve line abnormalities, address top line constraints, and reduce scrap and recurring quality issues using 6-Sigma and DMAIC methodologies.

• People Management: 
  • Ensure safe shift startup and shutdown confirmation.
  • Manage team versatility training and conduct bi-weekly versatility matrix reviews.
  • Schedule vacations and manage attendance/absenteeism.
  • Perform basic PeopleSoft administration (vacations, absences, overtime, schedules, etc.).
  • Execute seamless change management during line rebalances.
• Continuous Improvement: 
  • Participate in engineering change trials and support new process launches.
  • Coach and train Team Leaders across different programs and platforms.
  • Lead problem-solving initiatives using 6-Sigma tools, Global 8D, and DMAIC projects.
  • Address and improve priorities across dimensions, track scrap priorities, and improve the line's top constraint.
  • Ensure 5S implementation and sustainment in the work area.
  • Support recurring quality calls and lead monthly Kaizen events with Team Leaders (LET).
• Standardized Work & Daily Management: 
  • Ensure standardization at all levels and compliance with TDM bands.
  • Maintain deep process knowledge and manage abnormalities with base technicians.
  • Conduct process confirmation across dimensions and schedule daily Planned Job Observations (PJO) by priority.

  • Lead Daily, Weekly, Bi-Weekly, and Monthly Analysis Reports tracking Safety, Quality (FTT), Flow (FIS), Cost, and Issue Trackers.

    Key responsibilities:

  • Ensure safe shift startup/shutdown, supervise hourly personnel, and manage time/attendance in PeopleSoft.
  • Enforce standardized work, 5S, TDM bands, and daily Planned Job Observations (PJO).
  • Drive shop-floor problem solving (recurring quality calls, scrap reduction, and line top constraints) using 6-Sigma, Global 8D, and DMAIC.
  • Track daily and weekly KPIs across Safety, Quality (FTT), Flow (FIS), and Cost, executing monthly Kaizen projects with Team Leaders.
  • Build team versatility and train Team Leaders and technicians on new processes, rebalances, and platforms.

• Education: Bachelor's Degree in Engineering.
• Work Experience: Prior experience in Production / Manufacturing operations (Assembly) and supervising hourly personnel.
• Languages: English.

 Must Have Skills:

• Soft Skills: Leadership, teamwork, conflict management, and team motivation.
• Technical Knowledge: 6-Sigma methodology, Problem Solving, and Global 8D.
• People management and shop-floor operations control.

Highly Desirable Skills:

• Proficiency with plant systems and tools: Minitab, QLS, FIS, GSPAS / QPS, HOCR, Error Proofing, PeopleSoft, and FordDoc.
• Experience executing DMAIC projects, PJO, TDM, and Kaizen events.

Education preference:

• Bachelor's Degree in Engineering (Industrial, Mechanical, Mechatronics, Manufacturing, or related field).

Competency or skills to be gained:

• Mastery of technical and functional manufacturing systems: Minitab, QLS, FIS, GSPAS/QPS, HOCR, and Error Proofing.
• Advanced shop-floor leadership, team motivation, and conflict resolution skills.
• End-to-end management of manufacturing KPIs (Safety, Quality, Flow, Cost) and continuous improvement execution (DMAIC / Kaizen).

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