Operational Improvement Leader

March 3 2021
Industries Vehicles (parts, sales, maintenance)
Categories Engineering, HR, Training, Trades, Technicians, Construction, Training - Development - Improvement
Toronto, ON


Group Description

Cosma provides a comprehensive range of body, chassis and engineering solutions to global customers. Through our robust product engineering, outstanding tooling capabilities and diverse process expertise, we continue to bring lightweight and innovative products to market.

Deco Automotive, located in Rexdale and Brampton, Ontario is an automotive parts manufacturing facility that produces structural automotive components for Original Equipment Manufacturers (“OEM”) including BMW, Chrysler, Ford, General Motors, Tesla, and Toyota/Lexus. Deco Automotives’ capabilities include; Stamping, Hydroforming, Laser, CNC Machining, E Coating, Steel and Aluminum Assembly. We are certified in ISO/TS 16949 and ISO 14001.

Role Summary

Support the division in the achievement of financial and operational objectives. Lead a cross-functional team of managers to implement continuous improvement activities based on the Magna Factory Concept (MAFACT), conduct internal MAFACT assessments and create improvement plans across entire company. Lead lean CAPEX review for new projects and prepare it for approval by the Group Lead.

Key Responsibilities

  • As a certified MAFACT assessor, participate in at least one cross-group assessment per year, drive development improvement plans with process owners.
  • Develop and manage divisional A3 and feeder A3 through departmental process owners:
    • Manage monthly implementation tracking for all MAFACT sections with process owners and present MAFACT status at monthly manager meetings and present associated risks & opportunities.
    • Tracking of Significant CI Projects; Problem Solving Training including A3 (PDCA, Identify/support Top 3 Improvement Projects per Department of the division, 5 Why Problem-Solving Train division’s employees in Problem Solving.
  • Liaison with Group MAFACT Team to ensure Division remains current to standard, provide divisional feedback as required and address Divisional concerns requiring Group involvement.
  • Provide guidance and consultation to division personnel on MAFACT specification and coordinate or conduct training as required.
  • Apply advanced process knowledge of core processes to drive weekly Gemba walks by following the complete material flow.
  • Conduct required KAIZEN workshop events in accordance with divisional A3.
  • Conduct problem solving with team “at the source”, managing by facts and figures, encourage measurable improvements.
  • Create/ revisit standardized work for a high runner; identify and track significant improvement of performance related KPI via SW. SW rollout in the division.
  • Initiate/ revisit TPM for a high runner, identify and track significant improvement via TPM. Rollout TPM.
  • Reinforce Safety & 5S culture through structured Gemba programs.
  • Create VSM for value streams in the division, create a VSM roadmap to cover all high-runners and consequently work on VSM current-future PDCA.
  • Support PULL principle in the division, identify and track significant improvements via VSM.
  • Initiate “Train the Trainer” programs: provide training and coaching in the division for MAFACT & Lean principles.
  • MAFACT Simulation Training: train all team-leaders at the division; create and follow training plan to train all shop floor personnel + process engineers.
  • Visualization & Transparency:
    • Implement/ control MAFACT boards according to MAFACT Guideline.
    • Setup MAFACT Improvement Board according to the MAFACT Assessment and results.
    • Implement/ support GQS 06 Daily Fast Response.
    • Ensure KPI management at all departments.
    • Prepare Lean Capex Review checklist for submission to Subgroup Leads for approval.

Key Qualifications/Requirements

  • Engineering Degree in Mechanical or Industrial Engineering
  • Three to five (3 to 5) years related experience within an automotive assembly or similar manufacturing industry preferred.
  • Experience with Lean Manufacturing & Continuous Improvement principles, including:
    • Kaizen
    • 5S
    • TPM (Total Productive Maintenance)
    • Value Stream Mapping
    • Standardized Work & Production Systems
  • Demonstrated Systematic Problem Solving Skills
  • Ability to manage a high workload while working in a fast paced environment
  • Demonstrates the ability to work effectively in a team environment.
  • Strong organizational, verbal and written communication skills
  • Strong presentation skills
  • Ability to work overtime to meet business needs.

Additional Information

Accommodations for disabilities in relation to the job selection process are available upon request.

07--Operations F--Permanent/Regular

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