0781 Knitter - Direct

About the role

Under the direction of the KWW Department Manager and as part of the Kenansville floor management team, you will have full responsibility for internal quality and production targets. You will lead, manage, and develop the KWW team at Lear Kenansville, ensuring all internal and external requirements are met. Skills will be acquired through on-the-job training, review of SOPs, and working through daily responsibilities and challenges.

Responsibilities

• Follow all safety standards while ensuring your team follows all safety standards.
• Achieve stated results by communicating job expectations; planning, monitoring, and appraising job results; coaching, counseling, and disciplining employees; initiating, coordinating, and enforcing systems, policies, and procedures.
• Drive continuous improvement by eliminating waste from the process in all its forms to improve Safety, Quality, Cost (raw material usage, labor, energy), and machine overall efficiency (downtime analysis).
• Maintain workflow by monitoring steps of the process; setting processing variables; observing control points and equipment; monitoring personnel and resources; studying methods; implementing cost reductions; developing reporting procedures and systems; facilitating corrections to malfunctions within process control points; initiating and fostering a spirit of cooperation within and between departments.
• Complete production plans on time and to target by scheduling and assigning personnel; establishing priorities; monitoring progress; revising schedules; resolving problems; reporting results of the processing flow on shift production summaries.
• Work with the Launch/Product Engineering team to ensure all new products meet internal and external customer requirements.
• Ensure all product changes are controlled effectively through the engineering change process or deviation.
• Maintain quality by establishing and enforcing organizational standards; authority to stop processing if material quality is not to standard.
• Teach and enforce Stop-Call-Wait.
• Ensure operation of equipment by calling for repairs, evaluating new equipment and techniques.
• Provide manufacturing information by compiling, initiating, sorting, and analyzing production performance records and data; answering questions and responding to requests.
• Create/revise systems and procedures by analyzing operating practices, record-keeping systems, forms of control, and budgetary and personnel requirements; implementing change through deviation or ECR.
• Maintain a safe and clean work environment by educating and directing personnel on the use of all control points, equipment, and resources; maintaining compliance with established policies and procedures (Safety, Quality, and 5S).
• Regular involvement with the Safety & IATF Coordinator(s) to meet the requirements of the safety program (risk assessments, audits, LPAs, etc.) and reporting identified issues appropriately.
• Responsible for completing and achieving effective Accident/Incident investigations.
• Maintain staff by selecting, training, and mentoring employees.
• Manage Production personnel, schedules, and communicate updates to supporting team members (QC, Mechanical Support, and Purchasing).
• Maintain professional and technical knowledge.
• Drive and promote Kaizens through the team; support and drive all department six sigma/lean initiatives.
• Complete knowledge and understanding of Dyeing specifications and ensure adherence.
• Complete knowledge and understanding of product boundaries and Finishing equipment.
• Maintain accurate, legible audit data; complete all forms according to procedures.
• Segregate any product that does not meet specification; report any deviations from specification to the Senior Quality/Process Engineer and Department manager in a timely manner.
• Organize and direct strike-offs and the usage of Carton Req(s).
• Follow directions provided in work instructions.
• Monitor the operation of knitting machines for fabric defects not noticed by the scanner; stop the machine when a defect is noticed.
• Determine the reason for defects; repair and restart the machine if the defect is due to yarn problems; stitch the ends of any run in the fabric to prevent unraveling.
• Call the fixer if the defect cannot be repaired; restart the machine after repair and enter the reason for the machine stop.
• Enter required data, including defect count and yardage, to the greige roll ticket.
• Stop the machine at the required number of racks; call the warp changer to remove the full roll, place a new shaft in the let-off, and tie the new cloth end to the shaft; note the level of yarn on the warps.
• Perform any additional ad-hoc duties in line with role and company policies and procedures.

Requirements

• High school diploma or general education degree (GED); and six months to one-year position-related experience and/or training; or equivalent combination of education and experience.
• Skilled knowledge or direct experience in Dye and/or Finishing processes is a plus.
• Standard performance (within a 12-month training period) requires the operator to run at least 18 machines efficiently (2 bars @ 90% and 3 & 4 bars @ 85%).
• Understanding of textile manufacturing methods and defects.
• Problem-solving skills with an in-depth knowledge of 8D and Practical Problem Solving (PPS).
• Strong communication skills, both verbal and written.
• PC skills to include MS Excel/Word, PowerPoint, and Basics.
• Understanding of Lean improvement methods – Standardized work, 5S, SMED, 7 forms of waste, visual management, and Andon.
• KWW Operations – Ability to set up, thread, and operate Knit/weaving machines & warpers.
• Ability to read, write, and speak English to interpret documents such as specifications, safety rules, operating and maintenance instructions, reports, business correspondence, regulatory and procedure manuals.
• Ability to add, subtract, multiply, and divide in all units of measure, using whole numbers, common fractions, and decimals.
• Ability to communicate clearly and effectively with co-workers, Supervisors, and Management.
• Ability to work independently with little or no supervision and be a team player.
• Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exists.
• Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form.
• Ability to meet behaviors established in Company performance management and development process.
• Ability to effectively organize, set priorities, schedule assigned work; oversee multiple and rapidly changing priorities.
• Attention to detail and ability to execute tasks effectively.
• Ability to coach and develop associates in continuous improvement methods.
• Ability to implement change principles and practices of effective business communication; basic report writing methods and techniques; correct English usage, including spelling, grammar, and punctuation.
• Project management skills and ability to manage teams.
• Strong, confident presence with the ability to guide and influence others.

Physical Demands

• Frequent hand, finger, and wrist movement to handle or feel objects, tools, or controls.
• Requires standing (100%) and walking (10%).
• Frequently required to talk, listen/use hearing, stand, walk, stoop, kneel, or crouch, and/or use repetitive hand motions.
• Occasionally required to climb or balance.
• Constantly lift up to 10 pounds, frequently lift up to 20 pounds, and occasionally lift up to 50 pounds.

Working Conditions

• Constantly work under tight time constraints.
• Occasionally work mandatory overtime.
• May occasionally be exposed to extreme wet and/or humid conditions, heat/cold temperatures, and loud machine/equipment.
• Occasionally exposed to vibration, fumes, or airborne particles.

Personal Protective Equipment

• Eye protection
• Hearing Protection
• Steel toe/Non-Slip shoes
• Reflective Vest (where applicable)

Benefits

Lear Corporation champions teams and fosters collaboration, inclusion, respect, and excellence. We offer a path to a better career and future, empowering and driving our teams to succeed. We work hard for the people who work for us, providing groundbreaking technologies and earning recognition as one of the World’s Most Admired Companies.