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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