Process Coach, Maintenance at Ford Motor Company of Southern Africa

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 Production line is running safely and smooth.
• Supervise, Coach and be responsible for Maintenance team.
• Analyze breakdown reports and implement corrective measures.
• Adhere to all safety rules and regulations.

RESPONSIBILITIES

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 concern including, CCAR’s, PTA’S, near-misses etc.

Quality:

•  Ensure all quality standards are adhered to. Monitor the quality performance of 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 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 Maintenance department by finding ways to reduce usage of consumables and material.

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 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

PERFORMANCE MEASURES

•  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%

QUALIFICATIONS

KNOWLEDGE, SKILLS and ABILITIES 

• 3 years National Diploma in Mechanical/ Electrical or N6 with 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 Automotive industry
• 3-years’ Experience in Maintenance background
• Must have displayed proven capability of leading a team in current or previous roles.