Quality Control Group Leader

About the Role

Under general supervision, oversees the quality control operations during the designated shift, including maintaining the overall plant quality system and daily job assignments. Directs Team Leaders and other Team Members in assigned manufacturing areas to execute the group’s responsibilities. Manages the manufacturing line, cells, or area as an operational unit to accomplish company goals and targets in accordance with company policies, manufacturing standards, and quality standards for safety, product quality, customer satisfaction, accuracy, productivity, cost reduction, housekeeping, efficiency, training, teamwork, and morale.

Responsibilities

• Function as a first-line supervisor over team leaders and team members.
• Plan and coordinate hiring and placement of team members with the Assistant Manager.
• Monitor and track staffing conditions, work hours, overtime, job rotation, and absenteeism.
• Ensure consistent compliance with all company rules, policies, and practices; take corrective action when warranted.
• Manage and appraise team member job performance; recommend corrective action.
• Develop and maintain positive team member relations centered on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony.
• 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 the assigned area, accomplishing department hoshin goals and keeping on task with targets.
• Utilize Toyota Production System (TPS) techniques to standardize processes, reduce variation, identify waste, and eliminate it methodically.
• Develop standardized work procedures by designing and documenting the best work sequence for each process.
• Direct the work of Team Leaders and Team Members by assigning work stations and analyzing production requirements based on schedules.
• Direct floor activities through consistent application of Toyota Boshoku Business Practices (TBBP) to ensure effective manufacturing and correct sub-standard situations.
• Perform essential job functions of team leaders or team members as necessary to maintain efficient operations.
• Monitor the flow of parts, materials, productivity, and quality, including kanbans and inventory levels; take corrective action as needed.
• Ensure quality goals and standards are met; use quality feedback loops and escalation procedures.
• 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 required adjustments to maintain quality, safety, and efficiency.
• Evaluate and analyze problems involving machinery and equipment; coordinate repairs.
• Lead continuous improvement activities for the assigned area.
• Participate in setting Key Performance Indicator (KPI) targets, including safety, quality, operational availability, PEFF, and scrap.
• Maintain, monitor, and update department and KPI boards daily; initiate continuous improvement activities.
• Lead the implementation of team members’ ideas and management-directed initiatives.
• Maintain a safe working environment; ensure compliance with safety regulations, PPE requirements, and company policies.
• Lead, perform, or participate in ergonomic exercises, 5S housekeeping, accident investigations, and safety audits.
• Conduct ergonomic assessments of workstations and implement countermeasures to improve safety and well-being.
• Maintain knowledge of procedures for Hazardous Waste, Spill Response, and Plant Security.
• Train and coach team members on productivity, quality standards, TS19649, ISO 14001, environmental, safety, and continuous improvement.
• Oversee training of team members, including new hire training and cross-training.
• Maintain training matrices for team leaders and members; ensure training corrects sub-standard performance.
• Maintain, plan, and prepare department instruction manuals.
• Develop team members through performance evaluation, feedback, coaching, and cascade training.
• Collect, record, and analyze information; maintain documentation for assigned area activities.
• Prepare business reports and spreadsheets of required data.
• Maintain records, files, and logs of department/shift activities, such as production, problems, parts shortages, scrap, and quality.
• Monitor and maintain team member time, attendance, and training records.
• Communicate frequently with internal contacts on various issues; keep team members informed through daily meetings.
• Maintain communication with upstream and downstream groups to ensure efficient operations.
• Coordinate communications between shifts for assigned area(s).
• Support the Quality Manager and overall plant quality system.
• Establish and maintain quality standards that meet or exceed customer requirements.
• Communicate customer or supplier quality issues to relevant departments.
• Initiate containment and investigation activities to prevent quality problem outflow.
• Investigate and countermeasure internal quality defects to improve plant processes.
• Ensure proper quality processes and procedures are followed plant-wide.
• Work with all departments and levels of management to promote quality.

Requirements

• High school diploma, GED, or equivalent required.
• Associate’s degree required; or an equivalent combination of education and experience. Bachelor’s degree preferred.
• Minimum three years of relevant manufacturing experience required.
• Automotive industry experience preferred, with parts production, quality, or production control experience a plus.
• Minimum two years of leadership or supervisory experience required.
• Working knowledge and experience with TPS and Production Efficiency (PEFF) system preferred.

Skills

• Demonstrated knowledge, skills, and abilities to perform the job functions of a leadership role.
• General understanding and practical work experience with automotive quality systems and processes.
• Working knowledge of inspection standards and check fixtures.
• Ability to work a fixed or rotating shift schedule, including daily or weekend overtime.
• Thorough understanding of company product, trade terminology, quality management systems, manufacturing processes, and company policies.
• Basic math and analytical skills.
• Ability to facilitate problem-solving and resolution.
• Ability to work in a dynamic team and demanding customer environment.
• Ability to work in a fast-paced, multicultural work environment.
• Ability to work with multiple departments and prioritize activities.
• Ability to read instruction manuals, blueprints, and specifications.
• Ability to plan, supervise, and perform functions of assigned areas.
• Ability to maintain on-call flexibility to control abnormal conditions.
• Active listener with effective leadership, communication, and interpersonal skills.
• Ability to multi-task, handle diversity, and provide leadership through problem resolution.
• Ability to communicate and work well with all levels of the organization in a team environment.
• Ability to adapt skills and equipment to respond to unforeseen demands and problems.
• Ability to implement plans to control and maintain safety, quality, 5S, cost, and efficiency.
• Strong organization, time management, and planning skills; ability to manage multiple tasks with tight deadlines.
• Ability to teach team leaders and members 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 applications.
• ERP System experience (e.g., Oracle) preferred.
• Solid working knowledge of Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Lotus Notes/Outlook, Internet).

Training Requirements

• Forklift, tugger, and truck usage certification.
• Overhead crane operation.
• Cross-training for leading other plant support departments.
• RCRA and DOT hazardous waste requirements certification.
• Computer-based software, applications, and systems training (e.g., Oracle, Kronos, Future 3).

Work Environment

Office: Open Office Environment with moderate noise level.

Plant: 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 areas. Personal attire standards may apply. Involves moderate or occasional presence of slightly disagreeable conditions (e.g., cold, dust, heat, odor).

Travel: Minimal.

Physical Demands

• Required to talk, hear, and see (with visual acuity).
• Mental alertness and sustained attention to workflow, efficiency, and team member output.
• Physical ability to inspect, adjust, and operate equipment.
• Capable of walking, sitting, and standing for extended periods throughout the plant.
• Occasionally climbing, stooping, or bending near tooling and equipment.
• May be required to reach, grasp, and manipulate parts, materials, or equipment.
• May be occasionally required to lift up to 30-50 pounds.